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Emerson FCL with 1050 Analyzer 1056 Instruction Manual

1. 61 9 2 Pin Out Diagram for Model 3900VP 61 9 3 Simulating Chlorine enne nnne nnne nnn 70 9 4 Simulating a 71 9 5 Three Wire RTD I trai Rede 72 9 6 Simulating RTD Lu u cocer tak ad 72 Model FCL 1056 SECTION 1 0 DESCRIPTION AND SPECIFICATIONS SECTION 1 0 DESCRIPTION AND SPECIFICATIONS COMPLETE SYSTEM INCLUDES sensor connecting cable analyzer and flow controller CONTINUOUS pH CORRECTION eliminates expensive and messy reagents and trouble some sample conditioning systems MEASURES FREE CHLORINE IN SAMPLES having pH as high as 9 5 1 VARIOPOL QUICK DISCONNECT FITTINGS make replacing sensors easy FEATURE PACKED ANALYZER dual outputs four fully programmable alarm relays and large four line display 1 some cases the sensor be used in samples having pH as great as 10 0 Consult the factory 1 1 APPLICATIONS The FCL free chlorine system is intended for the deter mination of free chlorine in fresh water Unlike free chlorine analyzers from other manufacturers the FCL does not use expensive sample conditioning systems or messy reagents to control pH Instead the analyzer automatically compensates for changes in the pH of the sample The FCL is not intended for the determi nation of total chlorine or
2. 72 LIST OF FIGURES Number Title Page 2 1 Model FGE OT 7 2 2 Model FGEOZ Nc 7 3 1 Analog Output Connections iii ii i Ska ee ya eR aaa 9 3 2 Alarm Relay Connections anus cie ie ERA recente RRT 10 3 3 Wiring Diagram for Free Chlorine Sensor see 11 3 4 Wiring Diagram for 399VP 09 pH Sensor 11 3 5 Wiring Diagram for 3900VP 10 pH Sensor gray cable 11 3 6 Wiring Diagram for 3900VP 10 pH Sensor blue cable 11 4 1 DIS Play A uyu u D u un 13 4 2 Programming Screen Showing ltem List 13 4 3 AMON M 13 4 4 Analyzer Keypad uu s dr d ee eed eH ERR tee ix 14 4 5 Navigation ct e Fere ee Le UE Det ger 14 5 1 High Alariti LOGIC ii eter t aa 26 5 2 LOW Alarm LOGIC a A 26 5 3 Operation of the Interval Timer nennen 26 6 1 Sensor Current as a Function of Free Chlorine Concentration 39 6 2 Calibration Slope and Offset a 42 8 1 Chlorine Sensor Parts nitet iere iei a Ea nea esterase 55 8 2 Replacement Parts for the Flow Controller Assembly used in Model FCL 01 57 8 3 Replacement Parts for the Flow Controller Assembly used in Model FCL 02 58 9 1 Pin Out Diagram for Model 499ACL 01 VP Sensor
3. If the present temperature is more than 5 C different from the value entered an error message appears To force the analyzer to accept the calibration choose Yes To repeat the calibration choose No For troubleshooting assistance see Section 9 7 1 To return to the main display press MENU then EXIT MODEL FCL 1056 SECTION 6 0 CALIBRATION 6 3 CALIBRATION FREE CHLORINE 6 3 1 Purpose As Figure 6 1 shows a free chlorine sensor generates itull scale a current directly proportional to the concentration of free chlorine in the sample Calibrating the sensor requires exposing it to a solution containing no chlorine zero standard and to a solution containing a known amount of chlorine full scale standard 2 CI 5 0 o a slope sensor current ppm chlorine The zero standard is necessary because chlorine sen i sors even when no chlorine is in the sample generate full scale standard a small current called the residual current or zero cur rent The analyzer compensates for the residual current by subtracting it from the measured current before con verting the result to a chlorine value New sensors require zeroing before being placed in service and sensors should be zeroed whenever the electrolyte solution is replaced Either of the following makes a good zero standard Deionized water containing about 500 ppm sodium chloride Dissolve about 0 5 grams 1 8 teaspoonful of table salt in 1
4. D 4 11 Updated cover photo added Model 3900 pH sensor wiring diagrams blue and gray cables corrected flow cell part numbers added removing trapped bubbles information to troubleshooting section E 03 12 Update addresses mail and web MODEL FCL 1056 TABLE OF CONTENTS FCL 1056 TABLE OF CONTENTS Section Title Page 1 0 DESCRIPTION AND SPECIFICATIONS 1 enne 1 1 1 Applications T L u c 1 1 2 a A a Rese panera aspa 1 1 3 Specifications General n A a B 2 1 4 Specifications Senso uu eerie et ia di Fa auqaypa sikka 2 1 5 Specifications Analyzer iced da pp dab ed 2 1 6 Ordering Imformiatieti g 3 2 0 INSTALLATION LER 5 2 1 Unpacking and 5 2 2 Installation E enne MK E 6 3 0 WIRING EB 9 3 1 Power Alarm and Output 9 3 2 Sensor JSE PPP MO 10 4 0 DISPLAY AND OPERATION I U u nn nnn nnn nnne nnne nnn 13 4 1 Display P 13 4 2 rcr 14 4 3 Programming the Analyzer Tutorial s ssania 15 4 4 SOGCUr yu u 16 4 5 10 l 3 ae Hold A 17 4 6 Configuring the Matin Display uuu uuu etd i 18 5 0 PROGRAMMING THE ANALY
5. 01S14mA 0 000 ppm setting for output1 has changed to 8 5 ppm 08 50 ppm O2 51 4mA 0 0C 8 To return to the main menu press MENU To return to the main display 02 S1 20 100 0C press MENU then EXIT 4 4 SECURITY 4 4 1 How the Security Code Works Security codes prevent accidental or unwanted changes to program settings or calibrations There are three levels of security a Auser can view the default display and diagnostic screens only b Auser has access to the calibration and hold menus only c Auser has access to all menus Security Code 1 If a security code has been programmed pressing MENU causes the security screen to appear 2 Enter the three digit security code 3 If the entry is correct the main MENU screen appears The user has access to the sub menus the code entitles him to 4 Ifthe entry is wrong the invalid code screen appears 4 4 2 Assigning Security Codes See Section 5 7 4 4 3 Bypassing Security Codes Call the factory 16 MODEL FCL 1056 SECTION 4 0 DISPLAY AND OPERATION 4 5 USING HOLD 4 5 1 Purpose To prevent unwanted alarms and improper operation of control systems or dosing pumps place the alarms and outputs assigned to the sensor in hold before removing it for maintenance Hold is also useful if calibration for example buffering a pH sensor will cause an out of limits condition During hold outputs assigned to the sensor remain at the last value and a
6. Assigning a sensor and measurement chlorine pH or temperature to an output b Selecting a 4 20 mA or 0 20 mA output c Choosing a linear or logarithmic output d Adjusting the amount of dampening on the analog current output e Selecting the value the output current goes to if the analyzer detects a fault Ranging the outputs means assigning values to the low 0 or 4 mA and high 20 mA outputs Simulating an output means making the analyzer generate an output current equal to the value entered by the user 5 3 2 Definitions 22 ANALOG CURRENT OUTPUT The analyzer provides either a continuous 4 20 mA or 0 20 mA output signal proportional to chlorine temperature or pH ASSIGNING AN OUTPUT The outputs are freely assignable Outputs can be assigned to any sensor and to either the measurement or temperature LINEAR OUTPUT Linear output means the current is directly proportional to the value of the variable assigned to the output chlorine pH or temperature LOGARITHMIC OUTPUT Logarithmic output means the current is directly proportional to the common logarithm of the variable assigned to the output chlorine pH or temperature DAMPENING Output dampening smoothes out noisy readings It also increases response time The time selected for output dampening is the time to reach 63 of the final reading following a step change Output dampening does not affect the response time of the display FAULT The analyzer continu
7. For the sensor to work properly the chlorine must continuously diffuse through the membrane Bubbles block the chlorine in the sample from reaching the membrane so readings drift downward as bubbles form and grow The nozzle at the bottom of the flow cell pushes bubbles to the edges of the membrane where they do no harm In cold samples the nozzle may not be as effective a If bubbles are visible confirm that they are blocking the membrane by removing the sensor from the flow cell and replacing it Removing the sensor breaks the bubbles so when the sensor is replaced readings return to normal b Confirm that the nozzle is properly positioned in the flow cell Line up your eye with the bottom of the membrane retainer No gap should be visible between the end of the nozzle and membrane retainer 65 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 5 6 Sensor does not respond to changes in chlorine level 1 2 5 Is the grab sample test accurate Is the grab sample representative of the sample flowing to the sensor Is sample flowing past the sensor Be sure the liquid level in the constant head sampler is level with the central overflow tube and that excess sample is flowing down the tube If necessary disassemble and clean the over flow sampler See Section 8 4 Is the pH compensation correct If the analyzer is using manual pH correction verify that the pH value in the analyzer equals the actual pH to within 0 1 pH If the analyzer
8. Move the cursor to Program and press ENTER Program 2 Scroll to the bottom of the screen and continuing scrolling until Diagnostic Setup is highlighted Press ENTER Measurement Temperature Security Diagnostic Setup Diaan i 3 Diagnostics are available only for pH sensors In the FCL 02 the pH sen agnostic semp sor is sensor 2 Press ENTER S2 Diagnostic Setup 4 The oe Je pes o are nine items To show items beyond the first four in the list scroll to the Ref Offset 60mV bottom of the list and continue scrolling Diagnostic On Z Temp Corret n On To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited It is CIL ETT TR 500MO2 recommended that the settings be set to the values in the table Setting Default GI Fault High 1000 MQ 5 To return to the main display press MENU then EXIT 35 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 9 RESETTING THE ANALYZER 5 9 1 Purpose This section describes how to clear user entered values and restore default settings There are three resets 1 Resetting to factory default values clears ALL user entered settings including sensor and analog output calibration and returns ALL settings and calibration values to the factory defaults 2 Resetting a sensor calibration to the default values clears user entered calibration data for the selected sensor but leaves a
9. There will be between three and five items Units S1 Temp Comp and S2 Temp Comp always appear If manual temperature compensation was selected S1 Temp Comp Auto the manual temperature values entered for each sensor S1 and S2 S2 Temp Comp Auto Manual will also appear To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited To store a setting press ENTER 4 Foran explanation of terms see sections 5 6 2 and 5 6 3 5 To return to the main display press MENU then EXIT 57 CONFIGURING SECURITY SETTINGS 5 7 1 Purpose This section describes how to set security codes There are three levels of security a Auser can view the default display and diagnostic screens only b Auser has access to the calibration and hold menus only c Auser has access to all menus The securitv code is a three digit number The table shows what happens when different securitv codes XXX and YYY are assigned to Calibration Hold and All 000 means no security Calibration Hold What happens eee User enters XXX and has access to allmenus enters XXX and has access to all menus User enters XXX and has access to Calibration and Hold menus only User enters YYY and has access to all menus User needs no security code to have access to all menus needs no security code to have access to all menus _ 000 User needs no security code to
10. 1 or Output 2 Output 1 Output 2 Output 1 Hold at 5 Enter the desired simulated output current To end the simulated current press MENU or EXIT 5 4 CONFIGURING ALARMS AND ASSIGNING SETPOINTS 5 4 1 Purpose The Model FCL analyzer has an optional alarm relay board This section describes how to configure and assign setpoints to the alarm relays simulate alarm action and synchronize interval timers CONFIGURE THE ALARMS FIRST 1 Configuring an alarm means a Assigning a sensor and measurement chlorine pH or temperature to an alarm An alarm relay can also be used as a timer b Selecting high or low logic c Choosing a deadband d Setting the interval timer parameters 2 Simulating an alarm means making the analyzer energize or de energize an alarm relay 25 MODEL FCL 1056 5 4 2 Definitions 1 26 ASSIGNING ALARMS There are four alarms relays The relays are freely assignable to any sen sor and to either the measurement for example chlorine or temperature Alarm relays can also be assigned to operate as interval timers or as fault alarms A fault alarm activates when the analyzer detects a fault in either itself or the sensor FAULT ALARM A fault condition exits when the analyzer detects a problem with a sensor or with the analyzer itself that is likely to cause seriously erroneous readings If an alarm was programmed as a fault alarm the alarm will activate At the same time a fault messag
11. 2 Analog output wiring Two analog current outputs are located on the main circuit board which is attached to the inside of the enclosure door Figure 3 1 shows the location of the terminals The connectors can be detached for wiring TB 1 is output 1 TB 2 is output 2 Polarity is marked on the circuit board For best EMI RFI protection use shielded output signal cable enclosed in earth grounded metal conduit Keep output signal wiring separate from power wiring Do not run signal and power or relay wiring in the same conduit or close together in a cable tray HINGED END DIG SENSOR SENSOR vo 1 2 FIGURE 3 1 Analog output connections The analog outputs are on the main board near the hinged end of the enclosure door MODEL FCL 1056 SECTION 3 0 WIRING 3 1 3 Alarm wiring AWARNING Exposure to some chemicals may degrade the sealing properties used in the following devices Zettler Relays K1 K4 PN AZ8 1CH12DSEA The alarm relay terminal strip is located just below the NOI power connector on the power supply board See COMI Figure 3 2 NC NO2 Keep alarm relay wiring separate from signal wiring COM2 Do not run signal and power or relay wiring in the NC2 same conduit or close together in a cable tray NO3 COM3 NC3 NO4 COM4 NC4 FIGURE 3 2 Alarm relay connections 3 2 SENSOR WIRING The Model FCL is provided with sensor cables pre wired to the analyzer If it is necessary to replace the sensor c
12. 6 2 1 Purpose Temperature is important in the measurement of chlorine and pH for different reasons The free chlorine sensor is a membrane covered amperometric sensor As the sensor operates free chlorine diffuses through the membrane and is consumed at an electrode immediately behind the membrane The reaction produces a current that depends on the rate at which the free chlorine diffuses through the membrane The diffu sion rate in turn depends on the concentration of free chlorine and how easily it passes through the membrane the membrane permeability Because membrane permeability is a function of temperature the sensor current will change if the temperature changes To account for changes in sensor current caused by temperature alone the analyzer automatically applies a membrane permeability correction The membrane permeability changes about 3 C at 25 C so a 1 C error in temperature produces about a 3 error in the reading Temperature is also important in pH measurements 1 The analyzer uses a temperature dependent factor to convert measured cell voltage to pH Normally a slight inaccuracy in the temperature reading is unimportant unless the pH reading is significantly different from 7 00 Even then the error is small For example at pH 12 and 25 C a 1 C error produces a pH error less than 0 02 2 During auto calibration the analyzer recognizes the buffer being used and calculates the actual pH of the buffer at the measur
13. CALIBRATION 6 3 3 Procedure Calibrating the Sensor 1 Place the chlorine sensor in the chlorine flow cell If continuous live pH correction is being used calibrate the pH sensor section 6 4 and place it in the pH flow cell If manual pH correction is being used measure the pH of the sample and enter the value See section 5 5 Adjust the sample flow until water overflows the cen ter tube of the constant head flow controller 2 Adjust the chlorine concentration until it is near the upper end of the operating range Wait until the analzyer reading is stable before starting the calibration Calibrate Sensor 1 Sensor 2 Output 1 Output 2 S1 Calibration Free Chlorine Temperature 51 Calibration In Process 51 Enter Value S1 InProcess Cal Calibration Error Press Exit 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Choose the sensor vou wish to calibrate Sensor 1 is the chlorine sensor Sensor 2 if present is the pH sensor Choose Free Chlorine Choose In Process Cal Follow the screen prompts Once the reading is stable press ENTER Take the sample and press ENTER At this point the analvzer will store the present sensor current and temperature and use those values in the calibration Determine the free chlorine concentration in the sample and enter the value in the screen shown at left See Section 6 3 1 for sampling and testing precauti
14. See Section 3 2 5 15 the glass bulb cracked or broken Check the glass electrode impedance See Section 9 6 1 6 15 the analyzer working properly Check the analyzer by simulating the pH input See Section 9 9 9 6 4 Buffer Calibration Is Acceptable Process pH Is Slightly Different from Expected Value Differences between pH readings made with an on line instrument and a laboratory or portable instrument are normal The on line instrument is subject to process variables for example ground potentials stray voltages and orientation effects that may not affect the laboratory or portable instrument To make the process reading agree with a referee instrument see Section 6 4 5 68 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 6 5 Calibration Was Successful but Process pH Is Grossly Wrong and or Noisy Grossly wrong or noisy readings suggest a ground loop measurement system connected to earth ground at more than one point a floating system no earth ground or noise being brought into the analyzer by the sensor cable The problem arises from the process or installation It is not a fault of the analyzer The problem should disappear once the sensor is taken out of the system Check the following 1 Is a ground loop present a Verify that the system works properly in buffers Be sure there is no direct electrical connection between the buffer containers and the process liquid or piping b Strip back the ends of a heavy gauge wire Co
15. The position of the cursor is shown in reverse video See Section 4 2 and 4 3 for more information You are at the top of the list There are more items for viewing Scroll down You are at the bottom of the list There are more items for viewing Scroll up You are in the middle of the list There are more items for viewing Scroll up or down FIGURE 4 3 Arrow Bar The arrow bar shows whether additional items in a list are available 13 MODEL FCL 1056 SECTION 4 0 DISPLAY AND OPERATION 4 2 KEYPAD Local communication with the analyzer is through the membrane keypad Figures 4 4 and 4 5 explain the operation of the keys Press MENU The main menu screen appears Press DIAG The main diagnostic screen appears Navigation keys move the cursor in the Press EXIT to leave a screen direction indicated in without storing changes The Figure 4 5 display returns to the previous screen Press ENTER to store a change or select an item The display changes to the next screen FIGURE 4 4 Analyzer keypad Four navigation keys move the cursor around the screen The position of the cursor is shown in reverse video The navigation keys are also used to increase or decrease the value of a numeral Pressing ENTER selects an item and stores numbers and settings Pressing EXIT returns to the previous screen without storing changes Pressing MENU always causes the main menu to appear Moves cursor up or increases the value
16. access to the terminal strip disconnect the sensor Unplug the sensor board from the main board See Figure 3 2 6 Slide the replacement board partially into the board slot Plug the sensor board into the main board and reattach the sensor wires 7 Carefully pull the sensor cable through the gland fitting as you push the sensor board back into the enclosure Tighten the table glands 8 Close the front panel 9 Turn on power 53 MODEL FCL 1056 SECTION 8 0 MAINTENANCE 8 2 CHLORINE SENSOR 8 2 1 General When used in clean water the chlorine sensor requires little maintenance Generally the sensor needs mainte nance when the response becomes sluggish or noisy or when readings drift following calibration For a sensor used in potable water expect to clean the membrane every month and replace the membrane and electrolyte solu tion every three months In water containing large amounts of suspended solids for example open recirculating cooling water membrane cleaning or replacement will be more frequent 8 2 2 Cleaning the membrane Clean the membrane with water sprayed from a wash bottle Do not use tissues to clean the membrane 8 2 3 Replacing the electrolyte solution and membrane A CAUTION Fill solution may cause irritation May be harmful if swallowed Read and follow manual 1 Unscrew the membrane retainer and remove the membrane assembly and O ring See Figure 8 1 2 Hold the sensor over a container with th
17. avoid calibration errors caused by temperature drift The analyzer will not update readings until the drift is less than 0 02 pH over 10 seconds Were correct pH values entered during manual calibration Using auto calibration eliminates errors caused by improperly entering data Is the sensor properly wired to the analyzer See Section 3 2 Is the sensor dirty or coated See Section 8 3 2 Is the sensor faulty Check the glass impedance Press DIAG and choose Sensor 2 Glass impedance is the third item in the display Refer to the table below for an interpretation of the impedance readings GLASS IMPEDANCE Glass Imp less than 10 MQ Glass bulb is cracked or broken Sensor has failed between 10 and 1000 MQ Normal reading greater than 1000 MQ pH sensor may be nearing the end of its service life Another way of checking for a faulty sensor is to replace it with a new one If the new sensor can be calibrated the old sensor has failed Is the analyzer faulty The best way to check for a faulty analyzer is to simulate pH inputs See Section 9 9 67 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 6 2 Calibration Error during Standardization During standardization the millivolt signal from the pH cell is increased or decreased until the pH agrees with the pH reading from a referee instrument A unit change in pH requires an offset of about 59 mV The analyzer limits the offset to 60 mV If the standardization causes an offset greater t
18. diagnostic warnings applies only if a pH sensor is installed g Reset the analyzer to factory default settings 5 2 DEFAULT SETTINGS The analyzer leaves the factory with the default settings shown in Table 5 1 The setting can be changed by the user to any value shown in the column labeled CHOICES 19 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER TABLE 5 1 DEFAULT SETTINGS Sensor assignment DOupus FPR LLL os 5 SSS b mp 99 sns LL e tempus 9 o j ams RP 2 Assignments a AL1 and AL2 chlorine temp jali chlorine sensor 1 interval timer b AL3 and AL4 chione pH tamp fault temperature sensor 1 interval timer 20 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER TABLE 5 1 DEFAULT SETTINGS continued zmes E maw ss n Temperature related settings t 2 0 pH Sensor DiagnosticLimits 3 Glass impedance temperature on or off on correction Calibration Analog Outputs 21 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 3 CONFIGURING RANGING AND SIMULATING OUTPUTS 5 3 1 Purpose This section describes how to configure range and simulate the two analog current outputs CONFIGURE THE OUTPUTS FIRST 1 Configuring an output means a
19. have access to all menus 33 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 7 2 Procedure Configuring Security Settings Alarms Measurement Temperature Calibration Hold 5 8 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Scroll to the bottom of the screen and continue scrolling unit Security is highlighted Press ENTER Security 3 The screen shows the existing security codes To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the change The security code takes effect two minutes after pressing ENTER 4 To return to the main display press MENU then EXIT SETTING UP DIAGNOSTICS 5 8 1 Purpose NOTE Diagnostic setup applies only to pH sensors It appears only if you are using the FCL 02 This section describes how to do the following 1 2 Turn pH sensor diagnostics on and off Set pH sensor diagnostic limits 5 8 2 Definitions 1 34 DIAGNOSTICS pH sensor diagnostics are useful in troubleshooting calibration problems and in predicting when a pH sensor should be replaced Diagnostics can also alert the user that the sensor is no longer submerged in the process liquid REFERENCE OFFSET pH sensors are designed to have a potential of 0 mV in pH 7 buffer The reference offset is the actual potential in mV in pH 7 buffer A
20. in error For more information see Section 9 3 9 2 USING THE DIAGNOSTIC FEATURE Diagnostic 1 read diagnostic messages press DIAG The screen at left appears To Faults display fault messages select Fault To display Warning messages select warning To read measurement information about the sensor s including raw sensor signal and calibration data choose the desired sen Sensor 1 sor and press ENTER Sensor 2 Warnings 2 If you choose Fault or Warning a screen like the one shown at left 51 RTD Open appears S1 means sensor 1 S2 means sensor 2 For additional trou bleshooting information select the desired message and press ENTER 52 RTD Open For more information see Section 9 3 3 To return to the main display press MENU then EXIT 59 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 3 TROUBLESHOOTING WHEN A FAULT MESSAGE IS SHOWING Sensor EEPROM Write Error Sensor RTD Out of Range RTD is improperly wired or has failed too high The impedance of the pH reference function is too high very low suggesting a broken glass membrane 9 3 1 Main Board CPU Main Board Factory Data and Main Board User Data Errors These error messages mean the main board software is corrupted or the eeprom data on the main board is corrupted 1 Cycle the power off then on 2 If cycling the power does not help call the factory The main board must be replaced To do this the analyzer must be returned to the factory 3 If cy
21. is necessary to properly convert the sensor current into a free chlorine reading The analyzer uses either continuous live or manual pH correction In continuous live correction the analyzer continuously monitors the pH of the sample and corrects the free chlorine reading for changes in pH In manual pH correction the analyzer uses the pH entered by the user for the pH correction Generally if the pH changes more than about 0 2 units over short periods of time continuous live pH correction is recommended If the pH is relatively steady or subject only to seasonal changes manual pH correction is adequate During calibration the analyzer must know the pH of the solution If the analyzer is using automatic pH correction the pH sensor properly calibrated must be in the process liquid before starting the calibration If the analyzer is using manual pH correction be sure to enter the pH value before starting the calibration 6 3 2 Procedure Zeroing the Sensor 1 Place the sensor in the zero standard See Section 6 3 1 for suggested zero standards Be sure no air bubbles are trapped against the membrane The sensor current will drop rapidly at first and then gradually reach a stable zero value To monitor the sensor current press the DIAG key Choose Sensor 1 chlorine The input current is the first line in the display Note the units nA is nanoamps uA is microamps Typical zero current for a new sensor is between 10 and 10 nA A new se
22. is using automatic pH correction check the calibration of the pH sensor Is the membrane clean Clean the membrane and replace it if necessary Check that the holes at the base of the cathode stem are open Use a straightened paper clip to clear blockages See step 4 in Section 9 5 2 Replace the electrolyte solution Replace the sensor 9 5 7 Chlorine readings spike following sudden changes in pH automatic pH correction Changes in pH alter the relative amounts of hypochlorous acid and hypochlorite ion in the sample Because the sensor responds only to HOCI an increase in pH causes the sensor current and the apparent chlorine level to drop even though the actual free chlorine concentration remained constant To correct for the pH effect the analyzer automatically applies a correction Generally the pH sensor responds faster than the chlorine sensor After a sudden pH change the analyzer will temporarily over compensate and gradually return to the correct value The time constant for return to normal is about 5 minutes 9 5 8 Chlorine readings are too low 1 2 66 Was the sample tested as soon as it was taken Chlorine solutions are unstable Test the sample immediately after collecting it Avoid exposing the sample to sunlight Low readings can be caused by zeroing the sensor before the residual current has reached a stable minimum value Residual current is the current the sensor generates even when no chlor
23. of the selected digit Moves cursor to the left Moves cursor to the right Moves cursor down or decreases the value of the selected digit FIGURE 4 5 Navigation keys The operation of the navigation keys is shown To move a decimal point highlight it then press the up or down key 14 MODEL FCL 1056 SECTION 4 0 DISPLAY AND OPERATION 4 3 PROGRAMMING THE ANALYZER TUTORIAL Setting up and calibrating the analyzer is easy The following tutorial describes how to move around in the programming menus For practice the tutorial also describes how to assign ppm chlorine values to the 4 and 20 mA analog outputs Calibrate Hold Program Display Program Outputs Alarms Measurement Temperature Configure Stimulate Output Range 171 0 000 ppm O1 S1 20mA 10 00 ppm O2 S1 4mA 0 0C O2 S1 20mA 100 0C O1 5120 mA Press MENU The main menu screen appears There are four items in the main menu Calibrate is in reverse video meaning that the cursor is on Calibrate To assign values to the analog outputs the Program sub menu must be open Use the down navigation key to move the cursor to Program Press ENTER The Program menu appears There are between five and seven items in the Program menu Diagnostic Setup appears only if you have the FCL 02 with pH sensor The screen displays four items at a time The down ward pointing arrow on the right of the screen shows there are more items available
24. other cause not the fault of Seller are not covered by this limited warranty and shall be at Buyer s expense Seller shall not be obli gated to pay any costs or charges incurred by Buyer or any other party except as may be agreed upon in writing in advance by an authorized Seller representative All costs of dismantling reinstallation and freight and the time and expenses of Seller s per sonnel for site travel and diagnosis under this warranty clause shall be borne by Buyer unless accepted in writing by Seller Goods repaired and parts replaced during the warranty period shall be in warranty for the remainder of the original warranty peri od or ninety 90 days whichever is longer This limited warranty is the only warranty made by Seller and can be amended only in a writing signed by an authorized representative of Seller Except as otherwise expressly provided in the Agreement THERE ARE NO REPRESENTATIONS OR WARRANTIES OF ANY KIND EXPRESS OR IMPLIED AS TO MERCHANTABILITY FIT NESS FOR PARTICULAR PURPOSE OR ANY OTHER MATTER WITH RESPECT TO ANY OF THE GOODS OR SERVICES RETURN OF MATERIAL Material returned for repair whether in or out of warranty should be shipped prepaid to Emerson Process Management 2400 Barranca Parkway Irvine CA 92606 The shipping container should be marked Return for Repair Model The returned material should be accompanied by a letter of transmittal which should include the following information make a copy
25. sensor s screw into the flow cell adapters as shown in the figures For Model FCL 02 free chlorine with continuous pH adjustment the pH sensor must be installed as shown in Figure 2 2 A 1 4 inch OD tubing compression fitting is provided for the sample inlet If desired the compression fitting can be removed and replaced with a barbed fitting The fitting screws into a 1 4 inch FNPT check valve The check valve prevents the sensor flow cells from going dry if sample flow is lost The sample drains through a 3 4 inch barbed fitting Attach a piece of soft tubing to the fitting and allow the waste to drain open atmosphere Do not restrict the drain line Adjust the sample flow until the water level is even with the central overflow tube and excess water is flowing down the tube 2 2 4 Electrical Connections Refer to Section 3 1 for details 2 2 5 Installing the Sensor s The FCL is provided with sensor cables pre wired to the analyzer Connect the chlorine sensor Model 499ACL 01 54 VP to the cable labeled CL Connect the pH sensor Model 3900VP 02 10 or older Model 399VP 09 to the cable labeled pH The terminal end of the sensor is keyed to ensure proper mating with the cable receptacle Once the key has slid into the mating slot tighten the connection by turning the knurled ring clockwise The sensor s screw into the plastic fitting s which are held in the flow cell s by the union nut Do not remove the protective cap on the senso
26. the analyzer is working correctly 72 SECTION 9 0 TROUBLESHOOTING RTD SENSE RTD RETURN FIGURE 9 5 Three Wire RTD Configuration Although only two wires are required to connect the RTD to the analyzer using a third and some times fourth wire allows the analyzer to correct for the resistance of the lead wires and for changes in the lead wire resistance with temperature 10 IN REFERENCE FIGURE 9 6 Simulating RTD Inputs Temp C Pt 100 Q 0 100 0 10 103 9 20 107 8 25 109 7 30 111 7 40 115 5 50 119 4 60 123 2 70 127 1 80 130 9 85 132 8 90 134 7 138 5 NOTES 73 The right people the right answers right now Immediate Reliable Analytical Support Now there s a way to quickly get the right answers for your liquid analytical instrumentation questions the Analytical Customer Support Center Our staff of trained professionals is ready to provide the information you need If you are placing an order verifying delivery requesting application information or just want to contact a Rosemount Analytical representative a call to the Customer Support Center will provide you with the right people the right answers right now A Worldwide Network of Sales and Service Emerson Process Management s field sales offices are your source for more information on the fill line of Rosemount Analytical products Field sales personnel will work closely with you to supply technical data and application informat
27. timer The num bers in parentheses are the allowed values for each timer parameter MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 4 3 Procedure Configuring Alarms and Assigning Setpoints Program Outputs Alarms Measurement Temperature Configure Setpoint Simulate Synch Timers Yes Configure Setpoint Alarm 1 Alarm 2 Alarm 3 Alarm 4 Alarm 1 Settings Setpoint Assign 51 Measure Logic Low Deadband 0 000 ppm 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Choose Alarms Choose Configure Setpoint Choose Alarm 1 Alarm 2 Alarm 3 or Alarm 4 The screen summarizes the present configuration and setpoints There are nine items Setpoint Assign S1 is sensor 1 and S2 is sensor 2 Logic Deadband Interval time On time Recover time and Hold while active The last four items describe the operation of the timer Only four items are shown at a time To view the remaining items scroll to the bottom of the screen and continue scrolling To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 5 4 1 and 5 4 2 6 To return to the main display press MENU then EXIT 27 MODEL FCL 1056 5 4 4 Procedure Simulating Alarms 1 Program 2 Outputs Alarms Measurement Temperature Alarm
28. to the screen shown in step 8 Choose Buffer 2 Remove the sensor from the first buffer Rinse with water and place it in the second buffer Be sure the glass bulb and reference junction are completelv submerged Swirl the sensor Press ENTER Watch the pH reading for sensor 2 S2 at the top of the screen Once the reading is stable enter the pH value of the buffer at the buffer tempera ture and press ENTER If the calibration is successful the screen at left will be displaved for five seconds The displav will then return to screen in step 6 If the calibration is not successful the existing calibration data will not be changed A screen will appear identifving the error high slope low slope or offset error For troubleshooting see section 9 6 To return to the main displav press MENU then EXIT MODEL FCL 1056 6 4 5 Procedure Standardization SECTION 6 0 CALIBRATION 1 The pH value measured by the analyzer can be changed to match the reading from a second or referee instrument The process of making the two readings agree is called standardization 2 Place the sensor in the flow cell Wait until pH readings are stable Calibrate Sensor 1 Output 1 Output 2 S2 Calibration ORP Redox Temperature S2 pH Cal Buffer Cal Slope 56 19 mV pH Offset 2 mV 51 Enter Value S2 pH Cal 56 19 mV pH 2 mV Slope Offset 3 Press MENU The main menu screen appears The cursor will be on Calibrate Pres
29. 9 1 Pin Out Diagram for Model 499ACL 01 VP FIGURE 9 2 Pin Out Diagram for Model 3900VP Sensor top view of connector end of sensor Sensor top view of connector end of sensor 9 3 7 Sensor 1 Not Detected The ribbon cable from sensor 1 chlorine board must be plugged into the sensor 1 plug See Figure 3 1 for the location of the sensor board connectors 1 Confirm that the ribbon cable connecting sensor 1 chlorine board to the main board is plugged into the Sensor 1 connector on the main board 2 Confirm that the ribbon cable is seated at both ends 9 3 8 Sensor Factory Data Sensor Board User Data and Sensor EEPROM Write Error These messages mean factory eeprom data or user eeprom data on the sensor board is corrupted or the CPU on the sensor board is bad 1 Cycle power off then on 2 Replace the sensor board 9 3 9 Sensor ADC Error There is a bad component on the sensor board The sensor board must be replaced 61 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 3 10 Sensor RTD Out of Range Both the chlorine and pH sensor contain a Pt 100 RTD resistance temperature device for measuring temperature If the measured resistance is outside the expected range the analyzer will display the out of range error message 1 Check wiring connections 2 Disconnect the sensor from the cable and use an ohmmeter to check the resistance across the RTD See Figures 9 1 and 9 2 The resistance should be about 110 If there is an op
30. EMSON iii sa a a deed d 54 8 3 SOM SOM 55 8 4 Constant Head Flow Controller L Ll renta randan 56 9 0 TROUBLESHOOTING 59 9 1 e EE 59 9 2 Using the Dragnostic Feature oi een eee e 59 9 3 Troubleshooting When a Fault Message is 60 9 4 Troubleshooting When a Warning Message is 63 9 5 Troubleshooting When No Error Message is showing Chlorine 64 9 6 Troubleshooting When No Error Message is showing pH 67 9 7 Troubleshooting When No Error Message is showing General 70 9 8 Simulating Inputs 70 9 9 Simulating Inputs s Hii etr Reb rtt o Reda 71 9 10 Simulating Inputs Temperature nn 72 LIST OF TABLES Number Title Page 1 6 Ordering Information u uu uuu u nennen nen 3 1 6 Component II 3 1 6 ACCOSSOFIOS ii iri in Lo a ad 3 3 2 sensor WINING u ba p ea ABE pa WW g Fi 10 4 6 Display Abbreviations u sidek e
31. For samples having pH between 9 5 and 10 0 consult the factory The Model FCL is available in two options Model FCL 01 with manual pH correction and Model FCL 02 with continuous pH correction Choose the FCL 01 if the pH varies less than 0 2 or if pH changes are predictable or seasonal Choose the FCL 02 if the pH varies more than 0 2 To provide the continuous pH correction the Model FCL 02 requires a separate pH sensor Maintenance is fast and easy Replacing a membrane requires no special tools or fixtures A screw cap holds the pre tensioned membrane in place Replacing the electrolyte solution takes only minutes The FCL includes the easy to use Model 1056 analyz er The analyzer features two fully programmable 4 20 mA outputs and four fully programmable relays The back lit four line display allows the user to read sam ple pH and chlorine concentration at a glance Valves rotameters and pressure regulators to control sample flow are things of the past with the Model FCL A constant head overflow sampler ensures the correct sample flow to each sensor To eliminate wiring hassles quick disconnect Variopol cable is standard Stable free chlorine standards do not exist The chlorine sensor must be calibrated using the results of a labo ratory test run on a grab sample MODEL FCL 1056 1 3 SPECIFICATIONS GENERAL Sample requirements Pressure 3 to 65 psig 122 to 549 kPa abs A check valve in the inlet prevents the
32. H is relatively steady or subject only to seasonal changes manual pH correction is adequate 4 RESOLUTION If the chlorine concentration is less than 1 00 ppm mg L the display resolution can be set to O XX or 0 5 5 3 Definitions pH ORP 1 ORP ORP is oxidation reduction potential It is the voltage difference between a noble metal indicator electrode like platinum and a silver silver chloride reference electrode 2 REDOX Redox is redox potential It has the opposite sign from ORP 3 PREAMPLIFIER The pH signal has high impedance Before it can be used it must be converted into a low impedance signal The pre amplifier accomplishes this task and it can be located in either the analyzer or sensor In the FCL 02 the pre amplifier is located in the analyzer 4 SOLUTION TEMPERATURE CORRECTION The pH of a solution particularly an alkaline one is a function of temperature If the temperature changes so will the pH even though the concentration of the acid or base remains constant Solution temperature compensation converts the pH at the measurement temperature to the pH at a reference temperature 25 C Generally solution temperature compensation is used only in the deter mination of pH in condensate feedwater and boiler water in steam electric power plants 30 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 RESOLUTION The pH display resolution is user selectable XX X or XX XX 6 FILTER The ana
33. Instruction Manual PN 51 FCL 1056 rev E March 2012 FCL with 1056 Analyzer ROSEMOUNT _ Analytial EMERSON Process Management ESSENTIAL INSTRUCTIONS READ THIS PAGE BEFORE PROCEEDING Your purchase from Rosemount Analytical Inc has resulted in one of the finest instruments available for your particular application These instruments have been designed and tested to meet many national and international standards Experience indicates that its performance is directly related to the quality of the installation and knowledge of the user in oper ating and maintaining the instrument To ensure their continued operation to the design specifica tions personnel should read this manual thoroughly before proceeding with installation commissioning operation and maintenance of this instrument If this equipment is used in a manner not specified by the manufacturer the protection provided by it against hazards may be impaired Failure to follow the proper instructions may cause any one of the following situations to occur Loss of life personal injury property dam age damage to this instrument and warranty invalidation Ensure that you have received the correct model and options from your purchase order Verify that this manual covers your model and options If not call 1 800 854 8257 or 949 757 8500 to request correct manual For clarification of instructions contact your Rosemount representative Fol
34. Sensor WHITE RIDRIN WHITE RED RID SNS RED RIDIN BLUE GND SOL CLEAR NOT USED 5V OUT 5V OUT CLEAR PH SHIELD ORANGE IN pH ORP WHITE GRAY REF SHIELD GRAY IN REFERENCE GREEN CONNECT TO GREEN GROUNDING SCREW AT BOTTOM OF ENCLOSURE Figure 3 6 Wiring Diagram for 3900VP 10 pH sensor blue cable 11 MODEL FCL 1056 SECTION 3 0 WIRING 12 This page left blank intentionallv MODEL FCL 1056 SECTION 4 0 DISPLAY AND OPERATION SECTION 4 0 DISPLAY AND OPERATION 4 1 DISPLAY The analyzer has a four line display See Figure 4 1 The display can be customized to meet user require ments Refer to section 4 6 When the analyzer is being programmed or calibrated the display changes to a screen similar to the one shown in Figure 4 2 The live readings appear in small font at the top of the screen The rest of the display shows programming and calibration information Programming items appear in lists The screen can show only four items at a time and the arrow bar at the right of the screen indicates whether there are additional items in the list See Figure 4 3 for an explanation of the arrow bar 1 00 7 00 T1 25 0 C O1 12 00 mA T2 25 0 C O2 12 00 mA FIGURE 4 1 Main Displav measurement 7 00 pH 25 0C Output 1 Configure S1 Measurement Range 4 20 mA Live 1 00 ppm 25 0C Item list Scale Linear Dampening 0 sec M FIGURE 4 2 Programming Screen Showing Item List
35. ZZER I nnne nnne nennen 19 5 1 M H 19 5 2 Default Setthgs 1 tere reco atre ace ere rema a 19 5 3 Configuring Ranging and Simulating 22 5 4 Configuring Alarms and Assigning 25 5 5 Configuring the Measurerrnenit I tese e EL eve a pez deve ya be Ed EVE odd 30 5 6 Configuring Temperature Related Settings 32 5 7 Contiguring Security SettingS iii 2 tate eee inners 33 5 8 Setting up Diagnostics enm eene 34 5 9 Resetting the Analyzer cette titan itn u u nena 36 6 0 e Bpqgepee M 37 6 1 e A 37 6 2 Calibrating Temperature a ia az de d aa ee 37 6 3 Calibration Free Chlorine a eerie at eel ae 39 6 4 Calibration DH i i a 42 6 5 Calibration Analog 49 MODEL FCL 1056 TABLE OF CONTENTS TABLE OF CONTENTS CONT D Section Title Page 7 0 DIGITAL COMMUNICATIONS uuu uu Q 51 8 0 G0 53 8 1 ieaes 53 8 2 S
36. able refer to the instructions below Shut off power to the analyzer 2 Loosen the four screws holding the front panel in place and let it drop down Locate the appropriate signal board Slot 1 left Slot 2 center Slot 3 right input 1 chlorine TES 4 Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull the board forward to gain access to the wires and terminal screws Disconnect the wires and remove the cable 5 Insert the new cable through the gland and pull the cable through the cable slot 6 Wire the sensor to the signal board Refer to the wiring diagrams in Figures 3 3 and 3 4 7 Once the cable has been connected to the board slide the board fully into the enclosure while taking up the excess cable through the cable gland Tighten the gland nut to secure the cable and ensure a sealed enclosure 10 MODEL FCL 1056 T81 WHITE 1 WHITE RED ANOD S ANOD CATH SHLD CATH Figure 3 3 Wiring Diagram for Free Chlorine Sensor WHITE WHITE RED RED BLUE CLEAR NOT USED CLEAR ORANGE CLEAR GRAY GREEN CONNECT TO GREEN GROUNDING SCREW AT BOTTOM OF ENCLOSURE Figure 3 5 Wiring Diagram for 3900VP 10 pH sensor gray cable 3900VP 02 SECTION 3 0 WIRING WHITE WHITE RED RED CLEAR NOT USED BLUE NOT USED a3dWnf jain 10 Jin REFERENCE Figure 3 4 Wiring Diagram for 399VP 09 pH
37. ads and measure the resistance between them It should be less than 19 3 Even though the sense line is open the sensor is still usable Use a wire jumper to connect the sense and return terminals on the sensor terminal strip The temperature reading will no longer be corrected for the lead resistance nor will the analyzer be able to compensate for changes in ambient temperature The error could be several C 4 Replace the sensor 63 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 4 6 Sensor Temperature High or Low The sensor RTD is most likely miswired 1 Check wiring connections 2 Check resistance between RTD in and return leads The resistance should be close to the values given in Section 9 10 2 3 Replace sensor 9 4 7 Broken Glass Disabled The impedance of the pH glass electrode is a strong function of temperature As temperature increases the glass impedance decreases Because the broken glass fault message appears when the glass impedance becomes too low it is important that low impedance readings be properly corrected for temperature effects However there is a high temperature cutoff beyond which the correction does not work Once the temperature exceeds this value the broken glass fault is automatically disabled This warning should never appear in the FCL 02 9 5 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING CHLORINE Problem See Section Zero current was accepted but the current is substantially greate
38. alarm relays analog outputs chlorine onl 1056 03 24 32 AN 1056 03 24 32 AN 115 230 Vac 50 60 Hz alarm relays analog outputs chlorine and pH SENSOR MODEL DESCRIPTION 499ACL 01 54 VP Free chlorine sensor with Variopol connector 3900VP 02 10 pH sensor with Variopol connector SENSOR CABLE DESCRIPTION 23747 04 Interconnecting cable Variopol for 499ACL sensor 4 ft 23645 08 Interconnecting cable Variopol for 3900VP sensor 4 ft ACCESSORIES PART DESCRIPTION 9240048 00 Tag stainless steel specify marking MODEL FCL 1056 SECTION 1 0 DESCRIPTION AND SPECIFICATIONS This page left blank intentionally MODEL FCL 1056 SECTION 2 0 INSTALLATION SECTION 2 0 INSTALLATION 2 1 UNPACKING AND INSPECTION Inspect the shipping container If it is damaged contact the shipper immediately for instructions Save the box If there is no apparent damage unpack the container Be sure all items shown on the packing list are present If items are missing notify Rosemount Analytical immediately 2 1 1 FCL 01 free chlorine without continuous pH correction Model FCL 01 consists of the following items mounted on a back plate 1 Model 1056 03 24 38 AN analyzer with sensor cable attached 2 Constant head overflow sampler with flow cell for chlorine sensor The free chlorine sensor Model 499ACL 01 54 VP three membrane assemblies and a bottle of electrolyte solution are in a separate package 2 1 2 FCL 02 free chlorine with continuou
39. and reference junction are completely submerged Swirl the sensor Press ENTER Once the pH reading meets the stability requirements the screen changes to show the nominal pH of the buffer The nominal pH is the pH value at 25 C The displayed value is not correct press the up or down arrow key until the correct value is showing Press ENTER Remove the sensor from the first buffer Rinse with water and place it in the second buffer Be sure the glass bulb and reference junction are completely submerged Swirl the sensor Press ENTER Once the pH reading meets the stability requirements the screen changes to show the nominal pH of the buffer If the displayed value is not correct press the up or down arrow keys until the correct value is showing Press ENTER If the calibration is successful the screen at left will be displayed for five seconds The display will then return to the screen in step 6 If the calibration is not successful the existing calibration data will not be changed A screen will appear identifying the error high slope low slope or offset error For troubleshooting see section 9 6 If you chose Setup in step 8 the screen at left appears To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the change To return to the main display press MENU then EXIT MODEL FCL 1056 SECTION 6 0 CALIBRATION 6 4 4 Proc
40. ck of electrolyte flow to the cathode See step 4 in Section 9 5 2 Is the membrane fouled or coated A dirty membrane inhibits diffusion of free chlorine through the membrane reducing the sensor current and increasing the response time Clean the membrane by rinsing it with a stream of water from a wash bottle DO NOT use a tissue to wipe the membrane If cleaning the membrane does not improve the sensor response replace the membrane and electrolyte solution If necessary polish the cathode See Section 8 2 for details 9 5 4 Process readings are erratic 1 2 3 4 Readings are often erratic when a new sensor or a rebuilt sensor is first placed in service The current usually stabilizes after a few hours Are the holes between the membrane and the electrolyte reservoir open Refer to step 4 in Section 9 5 2 Verify that wiring is correct Pay particular attention to shield and ground connections If automatic pH correction is being used check the pH reading If the pH reading is noisy the chlorine reading will also be noisy If the pH sensor is the cause of the noise use manual pH correction until the problem with the pH sensor can be corrected Also refer to Section 9 6 7 for troubleshooting noisy pH readings Is the membrane in good condition and is the sensor filled with electrolyte solution Replace the fill solution and electrolyte Refer to Section 8 2 for details 9 5 5 Readings drift 1 Is the sample temperature changin
41. cling the power does not help and the fault message was Main Board User Data reset the analyzer to factory default and re enter user settings and repeat calibration Sensor board software is not supported by main board Sensor Incompatible software Sensor Not Communicating Sensor board is not communicating with main board 9 3 2 Hardware Error Hardware error means there is a missing or bad hardware component on the sensor board The board must be replaced 9 3 3 Sensor Board Unknown Sensor Board HW Hardware or SW Software Mismatch or Sensor Board Not Communicating These error messages mean the main board either does not recognize the sensor board or the sensor board and main board are no longer communicating 1 Verify that the ribbon cable connecting the main board on the inside of the front panel and the sensor board are properly seated Inspect the connecting cable for obvious tears or breaks 2 Ifthe ribbon cable is properly seated and appears undamaged the sensor board should be replaced 60 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 3 4 Sensor Incompatible This error message means that the sensor board software is not supported by the main board software Either the sensor board or the main board software is too old Replace the main board with one compatible with the sensor board Call the factory for assistance You will be asked for the main and sensor board software revision numbers To read the main boar
42. combined chlorine like monochloramine Nor can the FCL be used for the determination of chlorine in seawater 1 2 FEATURES The FCL uses a membrane covered amperometric sen sor A polarizing voltage applied to a platinum cathode behind the membrane reduces the chlorine diffusing through the membrane and keeps the concentration of chlorine in the sensor equal to zero The current gen erated by the cathode reaction is proportional to the rate of diffusion of chlorine through the membrane Because the concentration of chlorine in the sensor is zero the diffusion rate and the current are proportion al to the concentration of chlorine in the sample All amperometric free chlorine sensors respond to changes in pH Although free chlorine is a mixture of hypochlorous acid and hypochlorite ion hypochlorous acid alone is responsible for the sensor current Because the relative amounts of hypochlorous acid and hypochlorite ion depend on pH a pH change will cause the current and the apparent free chlorine con centration to change even though the true concentra tion remained constant Most manufacturers solve the pH dependence problem by treating the sample with acid which lowers the pH and converts hypochlorite ion into hypochlorous acid The Model FCL avoids the expense and inconvenience of sample conditioning by measuring the pH and applying a correction to the raw chlorine sensor signal The correction is valid between pH 6 0 and 9 5
43. d into the VP cable labeled pH sensor 2 Check wiring in the analyzer 3 Replace the pH sensor 9 4 4 Sensor Negative Reading The message applies to the chlorine sensor only The analyzer converts the raw sensor current to ppm chlorine by subtracting the zero current from the raw current and multiplying the result by a conversion factor If the zero current is larger than the raw current the result will be negative 1 Check the zero current It should be less than about 10 nA If it is greater than 10 nA repeat the zero step 2 Ifthe zero current is in the correct range the negative reading might be the result of the raw current or the sensitivity being too low A properly operating sensor should generate between 250 and 350 nA for every 1 ppm free chlorine at pH 8 Recalibrate the sensor If necessary clean or replace the membrane and check the fill solution 3 Replace the sensor 9 4 5 Sensor RTD Sense Open The analyzer measures temperature using a three wire RTD See Figure 9 4 The in and return leads are used to measure the resistance of the RTD The third lead called the sense line is connected to the return lead at the sensor The sense line allows the analyzer to correct for the resistance of the in and return leads and to compen sate for changes in lead resistance caused by changes in ambient temperature 1 Check sensor wiring particularly the red white and white red RTD leads 2 Disconnect the sense and return le
44. d software revision press the DIAG key and scroll down until Instr SW Ver is showing To view the sensor board software revision press the DIAG key choose the appropriate sensor and scroll down until Board SW Ver is showing The main board can be replaced only at the factory 9 3 5 Sensor CPU Error This message means the sensor board software is corrupted 1 Cycle the power off then on 2 If cycling the power does not help call the factory The sensor board must be replaced 9 3 6 Sensor RTD Open The chlorine and pH sensors used in the FCL contain a Pt 100 RTD resistance temperature device for measuring temperature Sensor RTD open means the temperature measuring circuit is open 1 Confirm that the sensor RTD wires are properly connected 2 Confirm that the Varipol connector is properly seated 3 Disconnect the sensor from the cable and use an ohmmeter to check the resistance across the RTD See Figures 9 1 and 9 2 At room temperature it should be about 1100 If the resistance is very high the RTD has failed and the sensor must be replaced If the resistance is okay connect the Variopol cable to the sensor and disconnect the three RTD wires at the analyzer Measure the resistance across the red and white RTD leads If the resistance is very high the problem is with the VP cable and it must be replaced ANODE 3 RID SENSE 5 ETURN 5 S RTD RTN 5 2 REF IN 6 CATHODE RTD IN 6 1 pH mV FIGURE
45. e cathode pointing down 3 Remove the fill plug and allow the electrolyte solution to drain out 4 Inspect the cathode If it is tarnished clean it using a cotton tipped swab dipped in baking soda or alumina Use type A dry powder alumina intended for metallographic polishing of medium and soft metals Rinse thor oughly with water 5 Wrap the plug with two turns of pipe tape and set aside Remove old tape first 6 Prepare a new membrane Hold the membrane assembly with the cup formed by the membrane and mem brane holder pointing up Fill the cup with electrolyte solution and allow the wooden ring to soak up the solu tion usually takes several minutes 7 Hold the sensor at about a 45 degree angle with the cathode end pointing up Add electrolyte solution through the fill hole until the liquid overflows Tap the sensor near the threads to release trapped air bubbles Add more electrolyte solution if necessary 8 Place the fill plug in the electrolyte port and begin screwing it in After several threads have engaged rotate the sensor so that the cathode is pointing up and continue tightening the fill plug Do not overtighten 9 Place a new O ring in the groove around the cathode post Cover the holes at the base of the cathode stem with several drops of electrolyte solution 10 Insert a small blunt probe like a toothpick with the end cut off through the pressure equalizing port See Figure 8 1 NOTE Do not use a sharp probe It wi
46. e will appear in the main dis play ALARM LOGIC SETPOINTS AND DEADBANDS See Figures 5 1 and 5 2 INTERVAL TIMER Any alarm relay can be used as an interval timer Figure 5 3 shows how the timer operates While the interval timer is operating the main display analog output and assigned alarms for the sensor s can be put on hold During hold the main display remains at the last value SYNCHRONIZE TIMER If two or more relays are being used as interval timers choosing synchro nize timers will cause each timer to start one minute later than the preceding timer SECTION 5 0 PROGRAMMING THE ANALYZER chlorine ppm alarm activates high alarm vepom deadband 0 3 ppm alarm deactivates time FIGURE 5 1 High alarm logic The alarm activates when the chlorine concentration exceeds the high set point The alarm remains activated until the reading drops below the value determined by the deadband chlorine alarm ppm deactivates 1 5 deadband low alarm 4 2 setpoint alarm activates time FIGURE 5 2 Low alarm logic The alarm activates when the chlorine concentration drops below the low set point The alarm remains activated until the reading increases above the value determined by the dead band on time duration on 0 999 sec relay activated HOLD E recovery i7 0 999 sec D on 0 timer interval 0 999 9 hr FIGURE 5 3 Operation of the interval
47. easurement choose Free Chlorine Do not choose pH Independ Free Cl b Leave Filter at the default value 5 sec unless readings are noisy c If you have an FCL 02 choose either Live Continuous or Manual for Free Cl Correct free chlorine correction Live Continuous means the analyzer will use the pH measured on the second channel to continuously correct the chlorine reading for changes in the sample pH Manual means the analyzer will use a fixed pH value entered by the user to convert the raw chlorine signal to a ppm reading d If you have an FCL 01 Free Correct free chlorine correction will not appear Instead enter the desired pH correction value for Manual pH 31 MODEL FCL 1056 SECTION 5 0 Measure PROGRAMMING THE ANALYZER S2 Configure 5 The screen summarizes the present configuration for sensor 2 pH There H are six items Measure Preamp Sol n Temp Corr Resolution Filter and Reference Z reference impedance Only four items are shown at Preamp Analyzer time To view the remaining items scroll to the bottom of the screen and Soln Temp Corr Off continue scrolling Resolution 0 01 pH i To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited To store the setting press ENTER a For pH Preamp choose Analyzer b For pH Reference Z choose Low c Leave Filter at the default value unless readings are noisy Fo
48. ectrolyte reservoir and membrane clear Often the flow of electrolyte can be started by simply holding the sensor with the membrane end pointing down and sharply shaking the sensor a few times as though shaking down a clinical thermometer If shaking does not work try clearing the holes around the cathode stem Hold the sensor with the membrane end pointing up Unscrew the membrane retainer and remove the membrane assembly Be sure the wood ring remains with the membrane assembly Use the end of a straightened paper clip to clear the holes at the base of the cathode stem Replace the membrane 64 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 5 3 Sensor can be calibrated but the current is too low 1 Is the temperature low or is the pH high Sensor current is a strong function of pH and temperature The sensor current decreases about 3 for every C drop in temperature Sensor current also decreases as pH increases Above pH 7 a 0 1 unit increase in pH lowers the current about 5 Sensor current depends on the rate of sample flow past the sensor tip If the flow is too low chlorine readings will be low Verify that the chlorine sensor is installed in the correct flow cell See Figure 2 1 and 2 2 Be sure the liquid level in the constant head sampler is level with the central overflow tube and that excess sample is flowing down the tube If necessary disassemble and clean the overflow sampler See Section 8 4 Low current can be caused by la
49. ed temperature Because the pH of most buffers changes only slightly with temperature reasonable errors in temperature do not produce large errors in the buffer pH For example a 1 C error caus es at most an error of 0 03 in the calculated buffer pH Without calibration the accuracy of the temperature measurement is about 0 4 C Calibrate the sensor analyzer unit if 1 0 4 accuracy is not acceptable 2 the temperature measurement is suspected of being in error Calibrate temperature by making the analyzer reading match the temperature measured with a standard thermometer 37 MODEL FCL 1056 6 2 2 Procedure SECTION 6 0 CALIBRATION 1 Remove the sensor from the flow cell Place it in an insulated container of water along with a calibrated thermometer Submerge at least the bottom two inches of the sensor 2 Allow the sensor to reach thermal equilibrium The time constant for both the chlorine and pH sensor is about 5 min so it may take as long as 30 min for equilibration Calibrate Sensor 1 Sensor 2 Output 1 Output 2 1 Calibration pH Independ Free Cl Temperature 51 Calibration 38 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Choose the sensor you wish to calibrate Sensor 1 is the chlorine sensor Sensor 2 if present is the pH sensor Choose Temperature Change the display to match the temperature read from the calibrated thermometer Press ENTER
50. edure Manual Calibration 1 Obtain two buffer solutions Ideally the buffer pH values should bracket the range of pH values to be measured 2 Remove the sensor from the flow cell If the process and buffer temperatures are appreciably different place the sensor in a container of tap water at the buffer temperature Do not start the calibration until the sensor has reached the buffer temperature 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Calibrate 4 Choose the sensor you wish to calibrate Sensor 1 is the chlorine sensor Sensor 1 Sensor 2 is the pH sensor Sensor 2 Output 1 Output 2 S2 Calibration 5 Choose pH Temperature 6 Choose Buffer Cal Buffer Cal Standardize Slope 56 19 mV pH Offset 2mV S2 pH Buffer Cal 7 Choose Manual Auto Manual 2 pH Manual Cal 8 Choose Buffer 1 Buffer 1 Buffer 2 9 Rinse the sensor with water and place it in the first buffer Be sure the glass bulb and reference junction are completely submerged Swirl the sensor 45 MODEL FCL 1056 Manual Buffer 1 S2 pH Manual Cal Buffer 1 Buffer 2 Manual Buffer 2 S2 pH Manual Cal Slope Offset 59 16 mV pH 10 mV 46 10 11 12 13 14 SECTION 6 0 CALIBRATION Watch the pH reading for sensor 2 S2 at the top of the screen Once the reading is stable enter the pH value of the buffer at the buffer temperature and press ENTER The displav returns
51. emove the sensor from the flow cell If the process and buffer temperatures are appreciably different place the sensor in a container of tap water at the buffer temperature Do not start the calibration until the sensor has reached the buffer temperature 3 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Calibrate 4 Choose the sensor you wish to calibrate Sensor 1 is the chlorine sensor Sensor 1 Sensor 2 is the pH sensor Sensor 2 Output 1 Output 2 2 Calibration 5 Choose pH 6 Choose Buffer Cal Buffer Cal Standardize Slope 56 19 mV pH Offset 2mV S2 pH Buffer Cal 7 Choose Auto 43 MODEL FCL 1056 S2 pH Auto Cal Start Auto Cal S2 pH Auto Cal Place Sensor in Buffer 1 Press Enter S2 pH Auto Cal S2 pH Auto Cal Place Sensor in Buffer 2 Press Enter S2 pH Auto Cal S2 pH Auto Cal Slope Offset 59 16 mV pH 10 mV S2 Setup Stable Time Stable Delta Buffer 10 sec 0 02 pH Standard 44 10 11 12 13 14 15 SECTION 6 0 CALIBRATION Choose Start Auto Cal If you wish to change the stability criteria or the pH buffer list from the default values choose Setup instead and go to step 14 The default stability is defined as a less than 0 02 pH change in 10 seconds The default buffer list is Standard See the table in section 6 4 2 Rinse the sensor with water and place it in the first buffer Be sure the glass bulb
52. en or short circuit the sensor has failed and should be replaced If the resistance is acceptable attach the sensor to the Variopol cable and disconnect the RTD IN and RTD RTN leads at the analyzer Connect an ohmmeter across the leads and measure the resistance If the circuit is open or shorted the cable must be replaced 3 If there is no open or short check the analyzer See Section 9 10 2 9 3 11 Glass Z Too High The sensing element in the pH sensor is a thin glass membrane Normally the impedance of the glass membrane is about 80 100 MQ As the glass membrane ages the impedance increases A large increase in glass impedance suggests that the sensor is near the end of its useful life 9 3 12 Reference Impedance Too High The Model 3900VP pH sensor supplied with the FCL 02 has a porous reference junction so the normal reference impedance is low less than 5 kQ High reference impedance suggests that the junction is severely fouled the fill solution has become depleted or the junction is not fully submerged in the sample 1 Confirm that sample is flowing to the pH flow cell 2 Clean the reference junction 3 Check the sensor in buffers If readings are accurate and the response is reasonably rapid lt 5 minutes to reach a stable reading the sensor is usable Clear the fault by increasing the reference impedance fault limit See Section 5 8 2 4 Replace the sensor if the response in buffers is bad 9 3 13 Broken Glass The s
53. ensing element in the pH sensor is a thin glass membrane Normally the impedance of the glass membrane is about 80 100 MQ If the glass membrane gets broken or cracked the impedance will drop to less than 10 MQ 1 Check sensor settings under the Measurement submenu Confirm that the pre amplifier location is set to analyzer 2 Confirm that the pH sensor is installed in the flow cell and sample is flowing through the cell 3 Check the sensor response in two buffers having different pH values If the membrane is cracked or broken the pH reading will be about the same in both buffers 4 Replace the pH sensor 62 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 4 TROUBLESHOOTING WHEN A WARNING MESSAGE IS SHOWING Sensor RTD Sense Open RTD sensor line is broken or not connected Sensor Temperature High Temperature is greater than 155 C 311 F Sensor Temperature Low Temperature is less than 20 C 4 F Broken Glass Disabled Advisory only applies to pH sensor only 9 4 1 Sensor No Solution Gnd This message implies that the pH sensor is miswired Check sensor wiring 9 4 2 Sensor Need Factory Cal The sensor board was improperly calibrated at the factory Call the factory for assistance 9 4 3 Sensor Out of Range This warning message applies to the pH sensor only It appears when the raw signal from the pH sensor is greatly outside the range expected for a properly operating sensor 1 Confirm that the pH sensor is plugge
54. g Membrane permeability is a function of temperature The time constant for the 499ACL 01 sensor is about five minutes Therefore the reading may drift for a while after a sudden temperature change Is the membrane clean For the sensor to work properly chlorine must diffuse freely through the membrane A coating on the membrane will interfere with the passage of chlorine resulting in slow response Clean the membrane by rinsing it with a stream of water from a wash bottle DO NOT use a tissue to wipe the membrane Is the sample flow within the recommended range Gradual loss of sample flow will cause a downward drift Be sure the liquid level in the constant head sampler is level with the central overflow tube and that excess sample is flowing down the tube If necessary disassemble and clean the overflow sampler See Section 8 4 Is the sensor new or has it been recently serviced New or rebuilt sensors may require several hours to stabilize Is the pH of the process changing If manual pH correction is being used a gradual change in pH will cause a gradual change in the chlorine reading As pH increases chlorine readings will decrease even though the free chlorine level as determined by a grab sample test remained constant If the pH change is no more than about 0 2 the change in the chlorine reading will be no more than about 10 of reading If the pH changes are more than 0 2 use automatic pH correction Is a bubble trapped against the membrane
55. g Power connector 3 leads 18 12 AWG wire size Current output connectors 2 leads 24 16 AWG wire size Alarm relay terminal blocks 18 16 AWG wire size Kynar is a registered trademark of Elf Atochem North America is a registered trademark of General Electric Viton is a registered trademark of duPont de Nemours amp Co N Teflon is a registered trademark of E I duPont de Nemours amp Co SECTION 1 0 MODEL FCL 1056 DESCRIPTION AND SPECIFICATIONS 1 6 ORDERING INFORMATION FCL Free Chlorine Measuring System The FCL is a complete system for the determination of free chlorine in aqueous samples It consists of the sensor s analyzer and constant head overflow device to control sample flow All components are mounted on a backplate Model option 02 includes a pH sensor for continuous auto matic pH correction Three replacement membranes and a 4 oz bottle of electrolyte solution are shipped with the chlorine sensor FCL FREE CHLORINE MEASURING SYSTEM pH CORRECTION required selection Without pH sensor With pH sensor pH CORRECTION required selection 1056 03 24 38 AN 115 230 Vac 50 60 Hz alarm relays analog outputs chlorine only option 01 only 1056 03 24 32 AN 115 230 Vac 50 60 Hz alarm relays analog outputs chlorine and pH option 02 only FCL 02 221 EXAMPLE COMPONENT PARTS ANALYZER MODEL DESCRIPTION 1056 03 24 38 AN 1056 03 24 38 AN 115 230 Vac 50 60 Hz
56. han 60 mV the analyzer will display the Offset Error screen The standardization will not be updated Check the following 1 18 the referee pH meter working and properly calibrated Check the response of the referee sensor in buffers 2 Isthe sensor fully immersed in the process liquid If the sensor is not completely submerged it may be measuring the pH of the liquid film covering the glass bulb and reference element The pH of this film may be different from the pH of the bulk liquid 3 Is the sensor fouled The sensor measures the pH of the liquid adjacent to the glass bulb If the sensor is heavily fouled the pH of liquid trapped against the bulb may be different from the bulk liquid 4 Has the sensor been exposed to poisoning agents sulfides or cyanides or has it been exposed to extreme temperature Poisoning agents and high temperature can shift the reference voltage many hundred millivolts 9 6 3 Sensor Does Not Respond to Known pH Changes 1 Is the pH sensor responsive to buffers Check sensor response in two buffers at least two pH units apart 2 Did the expected pH change really occur Use a second pH meter to verify the change 3 Is sample flowing past the sensor Be sure the liquid level in the constant head sampler is level with the central overflow tube and that excess sample is flowing down the tube If necessary disassemble and clean the over flow sampler See Section 8 4 4 15 the sensor properly wired to the analyzer
57. he Model FCL lyzer can be used with other sensors to measure other chlorine oxidants It can also be used to measure ORP oxidation reduction potential When used in the Model FCL the analyzer should be programmed to measure either free chlorine FCL 01 or free chlorine and pH FCL 02 Set automatic or manual pH correction for the free chlorine measurement 3 Setthe level of electronic filtering of the raw signals from the chlorine and pH sensors 4 Make various pH measurement settings The analyzer supplied with the Model FCL is designed to be as ver satile as possible The pH settings below are needed in some applications but are NOT used when pH is measured for the purpose of correcting free chlorine readings a solution temperature correction b analyzer isopotential point c reference impedance 5 5 2 Definitions Chlorine 1 CHLORINE OXIDANTS Although the FCL is used to measure free chlorine only the analyzer used in the FCL can be used to measure other chlorine oxidants for example monochloramine and total chlorine 2 FILTER The analyzer applies a filter to the raw sensor current The filter reduces noise but increases the response time The available filter s depend on the time setting If the filter is between 0 and 10 seconds the analyzer applies a window filter A window filter averages the measured value within the filter time For exam ple if the filter is 5 seconds and a step increase is applied to the inpu
58. he analyzer To simulate a pH measurement connect a standard millivolt source to the analyzer If the analyzer is working properly it will accurately measure the input voltage and convert it to pH 9 9 2 Simulating pH input 1 Set automatic temperature correction to manual and set manual temperature to 25 C Turn off solu tion temperature correction See Section 5 6 2 Disconnect the sensor and connect a jumper wire between the IN REFERENCE and IN pH terminals 3 Press DIAG and choose sensor 2 pH The input iii voltage should be 0 mV and the pH should be 7 00 Because calibration data stored in the analyzer may be offsetting the input voltage the displayed pH may FIGURE 9 4 Simulating pH Input not be exactly 7 00 E IN REFERENCE 4 standard millivolt source is available discon nect the jumper wire between IN REFERENCE and IN pH and connect the voltage source as shown in Figure 9 4 Be sure to jumper the INREFERENCE and GND SOL terminals 5 Calibrate the analyzer using the procedure in Section 6 4 4 Use 0 0 mV for Buffer 1 pH 7 00 and 177 4 mV for Buffer 2 pH 10 00 If the ana lyzer is working properly it should accept the cali bration The slope should be 59 16 mV pH and the offset should be zero 6 check linearity return to the main display and the pH temperature mV screen Set the voltage source to the values shown in the table and verify that the pH and millivolt readings match the values
59. in the table 71 MODEL FCL 1056 9 10 SIMULATING INPUTS TEMPERATURE 9 10 1 General The analyzer accepts a Pt100 RTD for pH and chlorine sensors The Pt100 RTD is in a three wire configuration See Figure 9 5 9 10 2 Simulating temperature To simulate the temperature input wire a decade box to the analyzer as shown in Figure 9 6 To check the accuracy of the temperature measurement set the resistor simulating the RTD to the values in the table and note the temperature readings The measured temperature might not agree with the value in the table During sensor calibration an offset might have been applied to make the measured temperature agree with a standard thermometer The offset is also applied to the simulated resistance The analyzer is measuring temperature correctly if the difference between measured tempera tures equals the difference between the values in the table to within 0 1 C For example start with a simulated resistance of 103 9 0 which corresponds to 10 0 C Assume the offset from the sensor calibration was 0 3 O Because of the offset the analyzer calculates temperature using 103 6 O The result is 9 2 C Now change the resistance to 107 8 which corresponds to 20 0 C The analyzer uses 107 5 Q to cal culate the temperature so the display reads 19 2 C Because the difference between the displayed tempera tures 10 0 C is the same as the difference between the simulated temperatures
60. in the menu To view the other items use the down key to scroll to the last item shown and continue scrolling down When you have reached the bottom the arrow will point up Move the cursor back to Outputs and press ENTER The screen at left appears The cursor is on Range Output Range is used to assign values to the low and high current outputs Press ENTER The screen at left appears The screen shows the present values assigned to output 1 O1 and output 2 O2 The screen also shows which sensors the outputs are assigned to S1 is sensor 1 and S2 is sensor 2 The assignments shown are the defaults for the FCL 01 For the FCL 02 Output 2 is assigned to sensor 2 pH Outputs are freely assignable under the configure menu For practice change the 20 mA setting for output 1 to 8 5 ppm a Move the cursor to the O1 81 20 mA 10 00 line and press ENTER b The screen at left appears c Use the navigation keys to change 10 00 to 8 5 ppm Use the left and right keys to move from digit to digit Use the up and down keys to increase or decrease the numeral d To move the decimal point press the left or right navigation key until the decimal point is highlighted Press the up key to move the decimal point to the right Press the down key to move to the left e Press ENTER to store the setting 15 MODEL FCL 1056 SECTION 4 0 DISPLAY AND OPERATION Output Range 7 The display returns to the summary screen at left Note that the 20 mA
61. induced noise in the sensor cable keep the unit as far away as possible from power cables relays and electric motors b If ground loops persist consult the factory A visit from an experienced technician may be required to solve the problem 9 6 6 pH Readings Are Moderately Noisy and Tend to Wander pH readings that are moderately noisy 0 1 pH and tend to wander are probably caused by bubbles getting trapped against the pH sensor Although the overflow sampler is designed to allow bubbles to escape before they reach the pH sensor and the sensor itself is designed so trapped air bubbles don t interfere with the measurement bubbles may occasionally be a problem Shaking the sensor will dislodge the bubbles If bubbles remain a problem contact the factory 69 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 7 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING GENERAL New temperature during calibration more than 2 3C different 9 7 1 from live reading Current output is too low Alarm relays do not operate when setpoint is exceeded 9 7 1 Difference Between Analyzer and Standard Thermometer is Greater Than 3 C 1 15 the standard thermometer RTD or thermistor accurate General purpose liquid in glass thermometers particularly ones that have been mistreated can have surprisingly large errors 2 Is the temperature element in the pH sensor completely submerged in the test liquid 3 Is the standard temperature sensor submerged to
62. ine is in the sample It is also called the zero current Because the residual current is subtracted from subsequent measured currents Zeroing before the current is a minimum can lead to low results Example The true residual current for a free chlorine sensor is 4 nA and the sensitivity is 350 nA ppm Assume the measured current is 200 nA The true concentration is 200 4 350 or 0 56 ppm If the sensor was zeroed prematurely when the current was 10 nA the measured concentration will be 200 10 350 or 0 54 ppm The error is 3 6 Now suppose the measured current is 400 nA The true concentration is 1 13 ppm and the measured concentration is 1 11 ppm The error is 1 8 However the absolute difference between the reading remains the same 0 02 ppm Sensor response depends on flow If the flow is too low readings will be low and flow sensitive Verify that the chlorine sensor is installed in the correct flow cell See Figures 2 1 and 2 2 Verify that the liquid level in the constant head sampler is level with the central overflow tube and that excess sample is flowing down the tube If necessary disassemble and clean the overflow sampler See Section 8 4 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 6 TROUBLESHOOTING WHEN NO ERROR MESSAGE IS SHOWING pH Problem See Section Calibration Error warning during two point calibration Offset Error warning during standardization Sensor does not respond to known pH changes Calibration was
63. ing standardization the difference between the two pH values is converted to the equivalent voltage The voltage called the reference offset is added to all subsequent measured sensor voltages before they are converted to pH If a pH sensor is buffered then standardized and placed back in the buffer solution the meas ured pH will differ from the buffer pH by an amount equivalent to the standardization offset Slope AmV ApH 42 MODEL FCL 1056 SECTION 6 0 CALIBRATION USER ENTERED SLOPE AND OFFSET If the slope and offset are known from other measurements they can be directly entered in the analyzer Enter the slope as a positive number corrected to 25 C To calculate the slope at 25 C from the slope at temperature t C use the equation 298 273 To calculate the offset use the following equation The offset can be either positive or negative slope at 25 C slope at t C offset mV PHbutter 7 00 slope at 25 C STABILITY SETTING During automatic calibration the analyzer measures noise and drift and does not accept calibration data until readings are stable Calibration data will be accepted as soon as the pH reading is constant to within the factory set limits of less than 0 02 pH change in 10 seconds The stability settings are programmable 6 4 3 Procedure Auto Calibration 1 2 Obtain two buffer solutions Ideally the buffer pH values should bracket the range of pH to be measured R
64. ion For more information please contact your nearest Emerson Process Management sales office THE AMERICAS HEADQUARTERS Emerson Process Management Rosemount Analytical Inc Liquid Center of Excellence 2400 Barranca Parkway Irvine CA 92606 Phone 1 949 757 8500 Toll Free 1 800 854 8257 Fax 1 949 474 7250 ASIA PACIFIC Emerson Process Management Asia Pacific Private Ltd 1 Pandan Crescent Singapore 0512 Republic of Singapore Phone 65 777 8211 Fax 65 777 0947 EUROPE Emerson Process Management Heath Place Bognor Regis West Sussex PO22 9SH England Phone 44 1243 863121 Fax 44 1243 845354 VISIT OUR WEBSITE AT www rosemountanalytical com GERMANY Emerson Process Management Process Gas Analyzer Center of Excellence GmbH amp Co OHG Industriestrasse 1 63594 Hasselroth Germany T 49 6055 884 0 F 49 6055 884 20 LATIN AMERICA Emerson Process Management Rosemount Analytical 10241 West Little York Suite 200 Houston TX 77040 USA T 713 467 6000 F 713 827 3328 MIDDLE EAST AND AFRICA Emerson Process Management EPM Building P O Box 17033 Jebe Ali Free Zone Dubai United Arab Emirates T 971 4 8835235 F 971 4 8835312 amp EMERSON Process Management WARRANTY Seller warrants that the firmware will execute the programming instructions provided by Seller and that the Goods manufactured or Services provided by Seller will be free from defects in materials
65. l appear If the user entered value is more that 1 mA different from the nominal value a possible error screen will appear To force the analyzer to accept the calibration choose Yes To return to the main display press MENU then EXIT 49 MODEL FCL 1056 SECTION 6 0 CALIBRATION 50 This page left blank intentionally MODEL FCL 1056 SECTION 7 0 DIGITAL COMMUNICATIONS SECTION 7 0 DIGITAL COMMUNICATIONS THE ANALYZER SUPPLIED WITH THE FCL DOES NOT HAVE THE DIGITAL COMMUNICATIONS OPTION 51 MODEL FCL 1056 SECTION 7 0 DIGITAL COMMUNICATIONS 52 This page left blank intentionally MODEL FCL 1056 SECTION 8 0 MAINTENANCE SECTION 8 0 MAINTENANCE 8 1 ANALYZER The analyzer used with the FCL needs little routine maintenance Clean the analyzer case and front panel by wiping with a clean soft cloth dampened with water ONLY Do not use solvents like alcohol that might cause a buildup of static charge Sensor circuit boards are replaceable ip 24207 00 pH ORP ISE sensor board 24203 01 chlorine sensor board To replace a board AWARNING RISK OF ELECTRICAL SHOCK Disconnect main power and relay contacts wired to separate power source before servicing Turn off power to the analyzer Loosen the four screws holding the front panel in place and let the front panel drop down Loosen the gland fitting and carefully push the sensor cable up through the fitting as you pull out the circuit board Once you have
66. larms assigned to the sensor remain in their present state Once in hold the sensor remains in hold until hold is turned off However if power is lost then restored hold will automatically be turned off 4 5 2 Using the Hold Function 1 Press MENU The main menu screen appears Move the cursor to Program Menu 2 Choose HOLD Calibrate Program 3 The screen shows the current hold status for each sensor Select the sensor to be put in hold Press ENTER S1 Hold outputs 4 To put the sensor in hold choose Yes To take the sensor out of hold and alarms choose No Once in hold the sensor remains in hold until hold is turned off However if power is lost then restored hold will automatically be turned off 17 MODEL FCL 1056 SECTION 4 0 DISPLAY AND OPERATION 4 6 CONFIGURING THE MAIN DISPLAY The main display can be configured to meet user requirements Main Format Language English Warning Enable Contrast 7 00 1 25 0 C O1 12 00 mA T2 25 0 C 02 12 00 mA 18 1 Press MENU The main menu screen appears Move the cursor to Display and press ENTER The screen shows the present configuration There are four items Main Format Language Warning and Contrast To make a change move the cursor to the desired line and press ENTER A screen appears in which the present setting can be edited Press ENTER to store the setting Main Format lets you configure the second line in the main display a
67. liter of water DO NOT USE DEIONIZED WATER ALONE FOR ZEROING THE SENSOR THE CONDUCTIVITY OF THE ZERO WATER MUST BE GREATER THAN 50 uS cm Tap water known to contain no chlorine Expose tap water to bright sunlight for at least 24 hours chlorine ppm FIGURE 6 1 Sensor Current as a Function of Free Chlorine Concentration The purpose of the full scale standard is to establish the slope of the calibration curve Because stable chlorine standards do not exist the sensor must be calibrated against a test run on a grab sample of the process liquid Several manufacturers offer portable test kits for this purpose Observe the following precautions when taking and testing the grab sample Take the grab sample from a point as close to the FCL as possible Be sure that taking the sample does not alter the flow of the sample to the unit It is best to install the sample tap just downstream from the tap for the FCL Chlorine solutions are unstable Run the test immediately after taking the sample Try to calibrate the sensor when the chlorine concentration is at the upper end of the normal operating range Free chlorine measurements also require a pH correction Free chlorine is the sum of hvpochlorous acid HOCI and hypochlorite ion The relative amount of each depends on pH As pH increases the concentration of decreases and concentration of increases Because the sensor responds only to pH correc tion
68. ll other user entered data unaffected 3 Resetting the analog output calibration clears only the user entered analog output calibration It leaves all other user entered settings unchanged 5 9 2 Procedure Resetting the Analyzer 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Scroll to the bottom of the screen and continue scrolling until Reset Temperature Security Analyzer is highlighted Press ENTER Diagnostics Reset Analyzer Reset Analyzer 3 Choose whether to reset all user entered values Factory Defaults Factory Defaults sensor calibration Sensor Cal Only or output calibration Output Cal y Only If you choose Sensor Cal Only or Output Cal Only a second Sensor Cal Only screen appears in which you can select which sensor or output Output Cal Only calibration to reset 4 To return to the main display press MENU then EXIT 36 MODEL FCL 1056 SECTION 6 0 CALIBRATION SECTION 6 0 CALIBRATION 6 1 INTRODUCTION The calibrate menu allows the user to do the following 1 Calibrate the temperature sensing element in the chlorine and pH sensors 2 Calibrate the chlorine sensor 3 Calibrate the pH sensor Four methods are available a Two point calibration with automatic buffer recognition b Manual two point calibration c Standardization d Manual entry of pH sensor slope and offset 4 Calibrate the analog outputs 6 2 CALIBRATING TEMPERATURE
69. ll puncture the bladder and destroy the sensor Gently press the probe against the bladder several times to force liquid through the holes at the base of the cathode stem Keep pressing the bladder until no air bubbles can be seen leaving the holes Be sure the holes remain covered with electrolyte solution 11 Place a drop of electrolyte solution on the cathode then place the membrane assembly over the cathode Screw the membrane retainer in place 12 The sensor may require several hours operating at the polarizing voltage to equilibrate after the electrolyte solution has been replenished 54 MODEL FCL 1056 SECTION 8 0 INFORMATION LABEL PRESSURE EQUALIZING PORT MAINTENANCE ELECTROLYTE FILL PLUG MEMBRANE ASSEMBLY WRAP WITH PIPE TAPE MEMBRANE RETAINER FIGURE 8 1 Chlorine Sensor Parts TABLE 8 1 Spare Parts 33523 00 Electrolyte Fill Plu 9550094 O Ring Viton 2 014 33521 00 Membrane Retainer 23501 08 Free Chlorine Membrane Assembly includes one membrane assembly and one O rin 23502 08 Free Chlorine Membrane Kit includes membrane assemblies and O rings 9210356 4 Free Chlorine Sensor Fill Solution 4 oz 120 mL 8 3 pH SENSOR 8 3 1 General When used in clean water the pH sensor requires little maintenance Generally the sensor needs maintenance when the response becomes sluggish or noisy In clean water the typical cleaning frequency is once a month In water containing large amounts
70. low all warnings cautions and instructions marked on and supplied with the product Use only qualified personnel to install operate update program and maintain the product Educate your personnel in the proper installation operation and maintenance of the product Install equipment as specified in the Installation section of this manual Follow appropriate local and national codes Only connect the product to electrical and pressure sources specified in this manual Use only factory documented components for repair Tampering or unauthorized substitution of parts and procedures can affect the performance and cause unsafe operation of your process All equipment doors must be closed and protec tive covers must be in place unless qualified per sonnel are performing maintenance If this equipment is used in a manner not speci fied by the manufacturer the protection provided by it against hazards may be impaired AWARNING RISK OF ELECTRICAL SHOCK 0 Equipment protected throughout by double insulation Installation of cable connections and servicing of this product require access to shock hazard voltage levels Main power and relay contacts wired to separate power source must be disconnected before servicing Do not operate or energize instrument with case open Signal wiring connected in this box must be rated at least 240 V Non metallic cable strain reliefs do not provide grounding bet
71. ly for cleaning Use a strong flow of water to flush out the tub ing A pipe cleaner or a small bottlebrush can remove more adherent deposits To prevent leaks apply a thin layer of silicone grease or equivalent to the two O rings at the base of overflow chamber and to the O ring sealing the central overflow tube to the base 8 4 3 Other Maintenance Table 8 2 and Figure 8 2 show the replacement parts for the flow controller assembly used in Model FCL 01 Table 8 3 and Figure 8 3 show replacement parts for the flow controller assembly used in Model FCL 02 56 MODEL FCL 1056 SECTION 8 0 MAINTENANCE TABLE 8 2 Replacement parts for constant head flow controller assembly Model FCL 01 Location in Shipping Figure 8 2 Description Weight 24039 00 Flow cell for chlorine sensor with bubble shedding nozzle 1 0 5 kg 24040 00 O ring kit two 2 222 and one 2 024 silicone O rings 1 1b 0 5 kg with lubricant 33812 00 Dust cap for constant head flow controller 1 1b 0 5 kg 9322032 Elbow 1 4 in FNPT x in OD tubing 1 1b 0 5 kg 9350029 Check valve 1 4 in FNPT 1 1b 0 5 kg 33823 00 Outside tube for constant head device 1 1b 0 5 kg FIGURE 8 2 Replacement Parts for the Flow Controller Assembly used in Model FCL 01 57 MODEL FCL 1056 SECTION 8 0 MAINTENANCE TABLE 8 3 Replacement parts for constant head flow controller assembly Model FCL 02 Location in Shipping Figure 8 3 Description Weight 24039 00 Flo
72. lyzer applies a software filter to the raw voltage value coming from the pH sensor The filter reduces noise but increases the response time See section 5 5 2 for more information 7 REFERENCE IMPEDANCE Usually the impedance of the reference electrode in a pH sensor is low However a few pH sensors have high reference impedance and the analyzer must be told that the reference impedance is high The pH sensor used in the FCL 02 has low reference impedance 5 5 4 Procedure Configuring the Measurement Program Outputs Alarms Measurement Temperature Configure Sensor 2 51 Configure Free Chlorine Units ppm Filter 5 sec Free Cl Correct Live C 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Choose Measurement The screen at left appears only if you have an FCL 02 Choose Sensor 1 chlorine or Sensor 2 pH The screen summarizes the present configuration for sensor 1 chlorine If you have FCL 02 the items are Measure Units Filter Free Cl Correct and Resolution If you have an FCL 01 the items are Measure Units Filter Manual pH and Resolution Only four items are shown at a time To view the remaining items scroll to the bottom of the screen and continue scrolling To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited To store the setting press ENTER a For M
73. n 01 For continuous pH correction choose option 02 Accuracy Accuracy depends on the accuracy of the chemical test used to calibrate the sensor SECTION 1 0 DESCRIPTION AND SPECIFICATIONS Interferences Monochloramine permangante peroxides Electrolyte volume 25 mL approx Electrolyte life 3 months approx for best results replace electrolyte monthly 1 5 SPECIFICATIONS ANALYZER Case Polycarbonate NEMA 4X CSA4 IP65 Display Monochromatic back lit LCD Main character height 0 6 in 15 mm Display is user programable Languages English German Italian Spanish French Portuguese Ambient temperature and humidity 32 to 131 F 0 to 55 C RH 5 to 95 con condensing Storage temperature 4 to 140 F 20 C and 60 C Power 84 to 265 Vac 47 5 65 0 Hz 15 W O Equipment protected by double insulation RFI EMI EN 61326 LVD EN 61010 1 C Outputs Two 4 20 mA or 0 20 mA isolated outputs Continuously adjustable Linear or logarithmic Maximum load 550 ohms Output dampening with time constant of 5 sec is user selectable Alarms Four alarm relays Any relay can be configured as a fault alarm instead of a process alarm Each relay can be configured independently and each can be programmed with interval timer settings Relays Form C SPDT epoxy sealed Relay Contact ratings jA 5A at 28 VDC or 300 VAC resistive 1 8 HP at 120 240 Terminal Connections Ratin
74. new sensor typically has a reference offset of a few mV Old sensors can have offsets of 60 mV or more GLASS AND REFERENCE IMPEDANCE During operation the analyzer continuously measures the imped ance of the pH glass membrane If the pH sensor has a solution ground the analyzer will also continuously measure the impedance of the reference junction The Model 3900VP pH sensor supplied with the FCL 02 has a solution ground The Model 399VP sensor supplied with earlier versions of the FCL 02 did not have a solu tion ground If you are using a 399VP sensor reference impedance diagnostics will not be available Glass and reference impedance measurements provide useful information about sensor health and cleanliness GLASS IMPEDANCE TEMPERATURE CORRECTION The impedance of a glass electrode is a strong function of temperature As temperature decreases the impedance increases For glass impedance to be a useful indicator of sensor condition the impedance must be corrected to a reference temperature GLASS FAULT HIGH A typical glass electrode has an impedance of about 100 MQ As the sensor ages glass impedance increases Extremely high impedance greater than about 1000MQ implies the sensor is nearing the end of its life High impedance may also mean that the sensor is not submerged in the process liquid MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 8 3 Procedure Setting Up Diagnostics 1 Press MENU The main menu screen appears
75. nnect one end of the wire to the process piping or place it in the process liquid Place the other end of the wire in the container of buffer with the sensor The wire makes an electrical connection between the process and sensor c If offsets and noise appear after making the connection a ground loop exists 2 15 process grounded a The measurement system needs one path to ground through the process liquid and piping Plastic piping fiberglass tanks and ungrounded or poorly grounded vessels do not provide a path A floating system can pick up stray voltages from other electrical equipment b Ground the piping or tank to a local earth ground c If noise still persists simple grounding is not the problem Noise is probably being carried into the instrument through the sensor wiring 3 Simplify the sensor wiring a Disconnect all sensor wires at the analyzer except IN REFERENCE IN pH RTD IN and RTD RETURN See the wiring diagrams in Section 3 2 b Tape back the ends of the disconnected wires to keep them from making accidental connections with other wires or terminals c Connect a jumper wire between the RTD RETURN and RTD SENSE terminals see wiring diagrams in Section 3 2 d If noise and or offsets disappear the interference was coming into the analyzer through one of the sensor wires The system can be operated permanently with the simplified wiring 4 Check for extra ground connections or induced noise a To avoid
76. nsor or a sensor in which the electrolyte solution has been replaced may require several hours occa sionally as long as overnight to reach a minimum zero current DO NOT START THE ZERO ROUTINE UNTIL THE SENSOR HAS BEEN IN THE ZERO SOLUTION FOR AT LEAST TWO HOURS 2 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER 39 MODEL FCL 1056 Calibrate Sensor 1 Sensor 2 Output 1 Output 2 S1 Calibration Free Chlorine Temperature 51 Calibration Zero In Process S1 Zero Cal Sensor zero done S1 Possible Error Proceed S1 Zero Cal Sensor zero failed Press Exit 40 SECTION 6 0 CALIBRATION Choose the sensor you wish to calibrate Sensor 1 is the chlorine sensor Sensor 2 if present is the pH sensor Choose Free Chlorine Choose Zero Cal The analyzer will automatically start the zero calibration If the zero calibration was successful the screen at left appears If the zero current is moderately larger than expected an error message appears To force the analyzer to accept the zero current choose Yes To repeat the calibration choose No For troubleshooting assistance see Section 9 5 If the zero current is much larger than expected the zero calibration failure screen appears The analyzer will not update the zero current For troubleshooting assistance see Section 9 5 To return to the main display press MENU then EXIT MODEL FCL 1056 SECTION 6 0
77. of suspended solids for example open recirculating cooling water cleaning fre quency will be substantially greater 8 3 2 Cleaning the Sensor Remove soft deposits by rinsing with a stream of water from a wash bottle If the sensor becomes coated with rust dissolve the rust by soaking the sensor in dilute citric acid dissolve 5 grams of citric acid crystals in 100 mL of water for no longer than 30 minutes at room temperature Rinse the sensor thoroughly with water and soak in pH 4 buffer for several hours Recalibrate the sensor in buffers before returning it to service 8 3 3 Other Maintenance The 3900VP 02 10 pH sensor supplied with the Model FCL 02 is disposable It has no replaceable parts 55 MODEL FCL 1056 SECTION 8 0 MAINTENANCE 8 4 CONSTANT HEAD FLOW CONTROLLER 8 4 1 General After a period of time deposits may accumulate in the constant head overflow chamber and in the tubing leading to the flow cell s Deposits increase the resistance to flow and cause the flow to gradually decrease Loss of flow may ultimately have an impact on the chlorine sensor performance The flow controller is designed to provide about 2 gal hr 120 mL mm flow Loss of flow to about 1 gal hr 60 mL mm causes about a 5 decrease in chlorine sensor output Loss of flow has almost no effect on pH sensor performance other than to increase the overall response time 8 4 2 Cleaning the flow controller The low flow controller can be taken apart complete
78. of the Return of Materials Request found on the last page of the Manual and provide the following thereon Location type of service and length of time of service of the device Description of the faulty operation of the device and the circumstances of the failure Name and telephone number of the person to contact if there are questions about the returned material Statement as to whether warranty or non warranty service is requested Complete shipping instructions for return of the material Adherence to these procedures will expedite handling of the returned material and will prevent unnecessary additional charges for inspection and testing to determine the problem with the device If the material is returned for out of warranty repairs a purchase order for repairs should be enclosed The right people ON LINE ORDERING NOW AVAILABLE ON OUR WEB SITE g http www rosemountanalytical com ROSEMOUNT ANALYTICAL CUSTOMER SUPPORT CENTER Specifications subject to change without notice 1 800 854 8257 GEMENT sy AM Credit Cards for U S Purchases Only a w PlantWeb i a gps VISA gt DNY Emerson Process Management 2400 Barranca Parkway Irvine CA 92606 USA 949 757 8500 gt 949 474 7250 http www rosemountanalytical com E M E RSO N Rosemount Analytical Inc 2012 Process Management
79. ons If the calibration is successful the live reading will change to the value entered in step 7 and the displav will return to the screen in step 6 If the sensitivity is too far outside the range of expected values the calibration error screen shown at left will appear The analyzer will not update the calibration For troubleshooting assistance see Section 9 5 To return to the main display press MENU then EXIT 41 MODEL FCL 1056 SECTION 6 0 CALIBRATION 6 4 CALIBRATION pH 6 4 1 Purpose A pH sensor consists of a glass and reference electrode Usually the two electrodes are combined into a single body called a combination pH sensor When the sensor is placed in an aqueous solution it produces a voltage proportional to pH An ideal pH sensor has a potential of 0 mV in pH 7 solution and a slope of 59 16 mV pH at 25 C that is a unit increase in pH causes the potential to drop 59 16 mV However even in a new pH sensor the slope and offset are rarely equal to the ideal values And as the sensor ages the offset typically increases and the slope decreases For these reasons a new pH sensor should be calibrated before use and the sensor should be recalibrated at regular intervals A pH sensor is calibrated by exposing it to standard solutions having known pH values The standard solutions are called buffers 6 4 2 Definitions 1 AUTOMATIC BUFFER CALIBRATION In automatic buffer calibration the analyzer recognizes the buffe
80. ontrast See next page for rest of menu tree MENU TREE continued Program Outputs Range assign values to 4 and 20 mA Configure Output 1 or 2 Assign sensor and measurement Range Scale Dampening Fault mode fixed or live Fault value output current Simulate Alarms Configure Setpoint Alarm 1 2 3 or 4 Setpoint Assign sensor and measurement High or low logic Deadband Interval time On time Recovery time Simulate Synchronize timers Measurement Free chlorine sensor 1 Measurement selection Units Filter Resolution pH sensor 2 Measurement selection Preamplifier location Solution temperature correction Resolution Filter Reference impedance high or low Temperature Units Temperature compensation auto or manual Set manual temperature if selected Security Calibrate Hold only All Diagnostic Setup Reference Offset Diagnostics on or off Glass impedance temperature correction Glass fault high Reference fault high Reset Analyzer About This Document This manual contains instructions for installation and operation of the Model FCL 1056 The following list provides notes concerning all revisions of this document Rev Level Date Notes A 9 08 This is the initial release of the product manual The manual has been reformatted to reflect the Emerson documentation style and updated to reflect any changes in the product offering B 11 09 Minor changes to manual 10 10 Updated DNV logo and copyright date
81. or workmanship under normal use and care until the expira tion of the applicable warranty period Goods are warranted for twelve 12 months from the date of initial installation or eighteen 18 months from the date of shipment by Seller whichever period expires first Consumables such as glass electrodes membranes liquid junctions electrolyte o rings catalytic beads etc and Services are warranted for a period of 90 days from the date of shipment or provision Products purchased by Seller from a third party for resale to Buyer Resale Products shall carry only the warranty extended by the original manufacturer Buyer agrees that Seller has no liability for Resale Products beyond making a reasonable commercial effort to arrange for procurement and shipping of the Resale Products If Buyer discovers any warranty defects and notifies Seller thereof in writing during the applicable warranty period Seller shall at its option promptly correct any errors that are found by Seller in the firmware or Services or repair or replace F O B point of man ufacture that portion of the Goods or firmware found by Seller to be defective or refund the purchase price of the defective por tion of the Goods Services All replacements or repairs necessitated by inadequate maintenance normal wear and usage unsuitable power sources unsuit able environmental conditions accident misuse improper installation modification repair storage or handling or any
82. ously monitors itself and the sensor s for faults If the analyzer detects a fault a fault message appears in the main display At the same time the output current goes to the value programmed in this section There are two output fault modes fixed and live Fixed means the selected output goes the previously programmed value between 0 00 and 22 00 mA when a fault occurs Live means the selected output is unaffected when a fault occurs RANGING AN OUTPUT The outputs are fully rangeable including negative numbers If the output is logarithmic assigned values must be positive MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 3 3 Procedure Configure Outputs 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 The cursor will be on Outputs Press ENTER Outputs Alarms Measurement Temperature 3 Choose Configure Configure Simulate Output 1 Configure 4 Choose Output 1 or Output 2 Output 1 Output 2 Output 1 Configure 5 The screen shows the present configuration There are six items Assign S1 Meas S1 is sensor 1 S2 is sensor 2 Range Scale Dampening Fault Mode and Fault Value To display the fifth and sixth items scroll to the Range 4 20 mA bottom of the screen and continue scrolling Scale Linear To make a change move the cursor to the desired line and press ENTER Dampening 0 sec f A screen will appear in which the present setting can be edited Pres
83. play more choices English Francais Espanol Deutsch S1 Measurement 5 Choose free chlorine for sensor 1 S1 pH Independ Free Cl Total Chlorine Monochloramine Units 6 Choose the desired units for chlorine ppm mg L S2 Measurement 7 The screens shown in steps 7 through 9 appear only if you have an FCL 02 If you have an FCL 01 go to step 10 Otherwise choose pH for sensor 2 52 Ammonia i S2 Preamp 8 Choose Analyzer Analyzer S1 Free Cl 9 Choose Live Continuous Go to step 11 pH Correction Manual Live Continous S1 Manual pH 10 The screen shown at left appears only if you have an FCL 01 Enter the pH of the process liquid Temp Units 11 Choose the desired temperature units 12 The main display appears The outputs and alarms if an alarm board is present are assigned to default values 13 To change outputs alarms and other settings go to the main menu and choose Program Follow the prompts A menu tree is on the following two pages To calibrate the sensor s refer to section 6 0 MENU TREE Calibrate Sensor 1 Free chlorine Chlorine Zero In process Temperature Sensor 2 pH pH Buffer Cal Auto Select buffer NIST DIN19267 Ingold Merck or Fisher Select stability criteria Manual Standardize Enter slope or offset Temperature Output 1 Output 2 Hold Sensor 1 Sensor 2 Display Main format configuration Language selection Warning enable or disable Screen c
84. r an explanation of terms see sections 5 5 2 and 5 5 3 6 To return to the main display press MENU then EXIT 5 6 CONFIGURING TEMPERATURE RELATED SETTINGS 5 6 1 Purpose This section describes how to do the following 1 2 3i 4 Choose temperature units Choose automatic or manual temperature correction for membrane permeability chlorine sensor Choose automatic or manual temperature compensation for pH Enter a temperature for manual temperature compensation 5 6 2 Definitions Chlorine 1 AUTOMATIC TEMPERATURE CORRECTION The free chlorine sensor is a membrane covered amperometric sensor It produces a current directly proportional to the rate of diffusion of free chlorine through the membrane The diffusion rate in turn depends on the concentration of chlorine in the sample and the membrane permeability Membrane permeability is a function of temperature As temperature increases permeability increases Thus an increase in temperature will cause the sensor current and the analyzer reading to increase even though the concentration of chlorine remained constant In automatic temperature correction the analyzer uses the temperature measured by the sensor to continuously correct for changes in membrane permeability MANUAL TEMPERATURE CORRECTION In manual temperature correction the analyzer uses the temper ature entered by the user for correction It does not use the actual process temperature Do NOT use manual tempe
85. r and uses the temperature corrected pH value in the calibration The table lists the buffers the analyzer recognizes Temperature pH data are valid between at least 0 and 60 C Buffer list Buffer pH standard note 1 68 3 56 3 78 4 01 4 64 6 86 7 01 7 41 9 18 10 01 12 45 DIN19267 1 09 3 06 4 65 6 79 9 23 12 75 Ingold 1 993 4 005 7 002 9 206 2 002 4 014 7 003 9 004 12 009 Fisher 1 00 2 00 3 00 4 00 5 00 6 00 7 00 8 00 9 00 10 00 11 00 Note With the exception of pH 7 01 buffer the standard buffers are NIST buffers The analyzer also measures noise and drift and does not accept calibration data until readings are stable Stability criteria are user programmable The use of automatic buffer calibration minimizes errors and its use is strongly recommended 2 MANUAL BUFFER CALIBRATION In manual calibration the user must enter the pH value of the buffer at the temperature of the buffer In addition the user must judge when pH readings are stable 3 SLOPE AND OFFSET Once the analyzer successfully completes the calibration it calculates and displays the calibration slope and offset The slope is reported as the slope at 25 C Figure 6 2 defines the terms FIGURE 6 2 Calibration Slope and Offset 4 STANDARDIZATION The pH measured by the analyzer can be changed to match the reading from a second or referee instrument The process of making the two readings agree is called standardization Dur
86. r s until ready to put the sensor s in service MODEL FCL 1056 SECTION 2 0 INSTALLATION INCH MILLIMETER CHLORINE SENSOR TMLE MODEL FCL 01 220 FIGURE 2 1 Model FCL 01 B ECL 9102 INCH MILLIMETER pH SENSOR CHLORINE SENSOR MODEL FCL 02 221 FIGURE 2 2 Model FCL 02 7 21 0202 A MODEL FCL 1056 SECTION 2 0 INSTALLATION This page left blank intentionally MODEL FCL 1056 SECTION 3 0 SECTION 3 0 WIRING 3 1 POWER ALARM AND OUTPUT WIRING AWARNING RISK OF ELECTRICAL SHOCK WIRING Electrical installation must be in accordance with the National Electrical Code ANSI NFPA 70 and or any other applicable national or local codes 3 1 4 Power Wire AC mains power to the power supply board which is mounted vertically on the left hand side of the analyz er enclosure The power connector is at the top of the board Unplug the connector from the board and wire the power cable to it Lead connections are marked on the connector L is live or hot N is neutral the ground con nection has the standard symbol AC power wiring should be 14 gauge or greater Run the power wiring through the conduit opening nearest the power terminal Provide a switch or breaker to disconnect the analyzer from the main power supply Install the switch or breaker near the analyzer and label it as the disconnecting device for the analyzer 3 1
87. r than 10 nA Error or warning message appears while zeroing the sensor zero current is too high Zero current is unstable Sensor can be calibrated but sensitivity is significantly different from 350 nA ppm Process readings are erratic Readings drift Sensor does not respond to changes in chlorine level Chlorine reading spikes following rapid change in pH 9 5 1 Zero current is too high 1 Is sensor properly wired to the analyzer See Section 3 2 2 Is the zero solution chlorine free Take a sample of the solution and test it for free chlorine level The concentration should be less than 0 02 ppm 3 Has adequate time been allowed for the sensor to reach a minimum stable residual current It may take several hours sometimes as long as overnight for a new sensor to stabilize 4 Check the membrane for damage and replace it if necessary 9 5 2 Zero current is unstable 1 Is sensor properly wired to the analyzer See Section 3 2 Verify that all wiring connections are tight Readings are often erratic when a new or rebuilt sensor is first placed in service Readings usually stabilize after about an hour 3 Is the conductivity of the zero solution greater than 50 uS cm DO NOT USE DEIONIZED OR DISTILLED WATER TO ZERO THE SENSOR The zero solution should contain at least 0 5 grams of sodium chloride per liter 4 Is the space between the membrane and cathode filled with electrolyte solution and is the flow path between the el
88. rature correction unless the measurement and calibration temperatures differ by no more than about 2 C Manual temperature correction is useful if the sensor temperature element has failed and a replacement sensor is not available 5 6 3 Definitions pH 1 32 AUTOMATIC TEMPERATURE COMPENSATION A pH sensor produces a voltage that depends on the pH of the sample The analyzer uses a temperature dependent factor to convert the voltage to pH In automatic temperature compensation the analyzer uses the temperature measured by the pH sensor to calculate the conversion factor For maximum accuracy use automatic temperature compensation MANUAL TEMPERATURE COMPENSATION In manual temperature compensation the analyzer converts measured voltage to pH using the temperature entered by the user It does not use the actual process tem perature Do NOT use manual temperature compensation unless the process temperature varies no more than about 2 C or the pH is between 6 and 8 Manual temperature compensation is useful if the sensor tempera ture element has failed and a replacement is not available MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 6 4 Procedure Configuring Temperature Related Settings 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 Choose Temperature Outputs Alarms Measurement Temperature Temperature 3 The screen summarizes the present sensor configuration
89. rect the interference AWARNING This product is not intended for use in the light industrial residential or commercial environments per the instrument s certification to EN50081 2 Emerson Process Management 2400 Barranca Parkway Irvine CA 92606 USA Fax 949 474 7250 EMERSON Process Management http www rosemountanalytical com Rosemount Analytical Inc 2012 QUICK START GUIDE FOR FCL ANALYZER Refer to Section 2 0 for installation instructions and Section 3 0 for wiring instructions Once connections are secured and verified apply power to the analyzer When the analyzer is powered up for the first time Quick Start screens appear Using Quick Start is easy A backlit field shows the position of the cursor b To move the cursor left or right use the keys to the left or right of the ENTER key To scroll up or down or to increase or decrease the value of a digit use the keys above and below the ENTER key Use the left and right keys to move the decimal point c Press ENTER to store a setting Press EXIT to leave without storing changes Pressing EXIT also returns the display to the initial Quick Start screen d A vertical black bar with a downward pointing arrow on the right side of the screen means there are more items to display Continue scrolling down to display all the items When you reach the bottom of the list the arrow will point up Language 4 Choose the desired language Scroll down to dis
90. s ENTER to store the setting For an explanation of terms see sections 5 3 1 and 5 3 2 6 Toreturn to the main displav press MENU then EXIT 23 MODEL FCL 1056 5 3 4 Procedure Ranging Outputs 1 Program 2 Outputs Alarms Measurement Temperature Configure Simulate Output Configure 4 Output 1 Output 2 Output Range 5 0 000 ppm O1 51 20mA 10 00 ppm O2 51 0 0C O2 S1 20mA 100 0C 24 SECTION 5 0 PROGRAMMING THE ANALVZER Press MENU The main menu screen appears Move the cursor to Program and press ENTER The cursor will be on Outputs Press ENTER Choose Range Choose Output 1 or Output 2 The screen shows the present settings for the outputs O1 is output 1 02 is output 2 S1 is sensor 1 and 82 is sensor 2 To make a change move the cursor to the desired line and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 5 3 1 and 5 3 2 To return to the main displav press MENU then EXIT MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 3 5 Procedure Simulating Outputs 1 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Program 2 The cursor will be on Outputs Press ENTER Outputs Alarms Measurement Temperature 3 Choose Simulate Simulate Configure Simulate Simulate 4 Choose Output
91. s well as the four smaller items at the bottom of the display Move the cur sor to the desired place in the screen and press ENTER Scroll through the list of items and select the parameter you wish displayed Once you are done making changes press EXIT twice to return to the display menu Press MENU then EXIT to return to the main display The following abbreviations are used in the quadrant display Cl temperature manual glass impedance pH e Impedance a t Choose Language to change the language used in the display Choose Warning to disable or enable warning messages Choose Contrast to change the display contrast To change the contrast choose either lighter or darker and press ENTER Every time you press ENTER the display will become lighter or darker MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER SECTION 5 0 PROGRAMMING THE ANALYZER 5 1 GENERAL This section describes how to make the following program settings using the local keypad a Configure and assign values to the analog current outputs b Configure and assign values to the alarm relays c Choose the type of chlorine measurement being made This step is necessary because the analyzer used with the FCL can measure forms of chlorine other than free chlorine d Choose temperature units and automatic or manual temperature correction for chlorine and pH if a pH sensor is installed e Set two levels of security codes f Assign limits to
92. s 3 Configure Setpoint Synch Timers Yes Simulate 4 Alarm 2 Alarm 3 Alarm 4 Simulate Alarm 1 5 Don t Simulate 28 SECTION 5 0 PROGRAMMING THE ANALYZER Press MENU The main menu screen appears Move the cursor to Program and press ENTER Choose Alarms Choose Simulate Choose Alarm 1 Alarm 2 Alarm 3 or Alarm 4 Choose Don t simulate De energize or Energize Press MENU or EXIT to end simulation MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 4 4 Procedure Synchronizing Timers 1 Synch Timers is available only if two or more alarm relays have been configured as interval timers Program Outputs Measurement Temperature Alarms Configure Setpoint Simulate Synch Timers 2 3 Press MENU The main menu screen appears Move the cursor to Program and press ENTER Choose Alarms The summary display shows the current Synch Timers setting Yes or No To make a change choose Synch Timers and press ENTER A screen will appear in which the present setting can be edited Press ENTER to store the setting For an explanation of terms see sections 5 4 1 and 5 4 2 To return to the main display press MENU then EXIT 29 MODEL FCL 1056 SECTION 5 0 PROGRAMMING THE ANALYZER 5 5 CONFIGURING THE MEASUREMENT 5 5 1 Purpose This section describes how to do the following 1 Program the analyzer to measure free chlorine and pH This step is necessary because t
93. s ENTER Choose the sensor you wish to calibrate Sensor 1 is the chlorine sensor Sensor 2 is the pH sensor Choose pH Choose Standardize Once reading is stable measure the pH of the liquid using a referee instrument Because the pH of many natural and treated waters depends on temperature measure the pH of the sample immediately after taking it For poorly buffered samples determine the pH of a continuously flowing sample from a point as close as possible to the sensor Change the reading to match the reading of the referee instrument If the calibration is successful the screen at left will be displayed for five seconds The display will then return to screen in step 3 If the calibration is not successful the existing calibration data will not be changed A screen will appear identifying the error high slope low slope or offset error For troubleshooting see section 9 5 To return to the main display press MENU then EXIT 47 MODEL FCL 1056 SECTION 6 0 CALIBRATION 6 4 6 Procedure Entering a Known Slope and Offset 1 Calibration data i e slope and offset at pH 7 can be entered directly into the analyzer if the data for the sensor are already known Calibrate Sensor 1 Sensor 2 Output 1 Output 2 S2 Calibration Temperature Buffer Cal Standardize Slope 56 19 mV pH Offset 2mV 48 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Choose the sen
94. s pH correction Model FCL 02 consists of the following items mounted on a back plate 1 Model 1056 03 24 32 AN analyzer with sensor cables attached 2 Constant head overflow sampler with flow cells for pH and chlorine sensors 3 Stand to hold pH buffer solution during calibration The free chlorine sensor Model 499ACL 01 54 VP shipped with three membrane assemblies and a bottle of electrolyte solution and the Model 3900VP 02 10 pH sensor which replaces the older Model 399VP 09 sensor are in separate packages MODEL FCL 1056 SECTION 2 0 INSTALLATION 2 2 INSTALLATION 2 2 1 General Information 1 Although the system is suitable for outdoor use do not install it in direct sunlight or in areas of extreme ACAUTION temperature The FCL free chlorine system is NOT suitable for use in hazardous areas To keep the analyzer enclosure watertight install plugs provided in the unused cable openings Install the system in an area where vibrations and electromagnetic and radio frequency interference are minimized or absent 4 sure there is easy access to the analyzer and sensors 2 2 2 Sample Requirements Be sure the sample meets the following requirements 1 Temperature 32 to 122 F 0 to 50 C 2 Pressure 3 to 65 psig 122 to 549 kPa abs 3 Minimum flow 3 gal hr 11 L hr 2 2 3 Mounting Inlet and Drain Connections The FCL is intended for wall mounting only Refer to Figure 2 1 or 2 2 for details The
95. sensor flow cells from going dry if sample flow is lost The check valve opens at 3 psig 122 kPa abs If the check valve is removed minimum pres sure is 1 psig 108 kpa abs Temperature 32 to 122 F 0 to 50 Minimum Flow 3 gal hr 11 L hr Maximum flow 80 gal hr 303 L hr high flow causes the overflow tube to back up Sample Conductivity gt 50 uS cm at 25 C Process connection 1 4 in OD tubing compression fitting can be removed and replaced with barbed fitting for soft tubing Drain connection 3 4 in barbed fitting Sample must drain to open atmosphere Wetted parts Overflow sampler and flow cell acrylic polycar bonate Kynar 1 nylon silicone Chlorine sensor Noryl 2 Viton 3 wood silicone polyethersulfone polyester and platinum pH sensor 3900VP Stainless steel glass Teflon 4 polyphenylene sulfide EPDM and silicone Response time to step change in chlorine concen tration lt 80 sec to 95 of final reading for inlet sample flow of 3 gph 11 L hr Weight shipping weight Model FCL 01 10 Ib 13 Ib 4 5 kg 6 0 kg Model FCL 02 11 Ib 14 Ib 5 0 kg 6 5 kg rounded to the nearest 1 Ib 0 5 kg 1 4 SPECIFICATIONS SENSOR Free chlorine range 0 to 10 ppm as Cl For higher ranges consult the factory pH correction range 6 0 to 9 5 For samples having pH between 9 5 and 10 0 consult the factory If pH 6 0 correction is not necessary For manual pH correction choose optio
96. si eden ka eoe eta eee e i ced eed aa ec 18 5 1 BI3r eec 20 54 Default Settings gon uylla 21 5 7 Configuring Security Settings L nn nnnn nennen 33 5 8 2 Procedure Setting Up 35 642 Calibration e uut eter eee i a 42 8 1 ied 53 8 21 Spare Parts iso e te co Gia Ceo e EHI Oed nade 55 8 3 Replacement Parts for Constant Head Flow Controller Assembly Model FCL 01 ERR 57 8 3 Replacement Parts for Constant Head Flow Controller Assembly Model FCL 02 T E ta 58 9 3 Troubleshooting When a Fault Message is Showing 60 9 4 Troubleshooting When a Warning Message is 63 9 5 Troubleshooting When No Error Message is Showing Chlorine 64 9 6 Troubleshooting When No Error Message is Showing 67 MODEL FCL 1056 TABLE OF CONTENTS LIST OF TABLES CONT D 9 6 1 Calibration Error During Two Point Calibration 67 9 7 Troubleshooting When No Error Message is Showing 70 9 92 Simulating pH aus eene dee E d 71 9 10 Simulating Inputs
97. sor vou wish to calibrate Sensor 1 is the chlorine sensor Sensor 2 is the pH sensor Choose pH Choose Slope or Offset Enter the known slope and offset values Alwavs enter the slope as a positive number Press ENTER to store the number See Section 6 4 2 for more information To return to the main displav press MENU then EXIT MODEL FCL 1056 SECTION 6 0 CALIBRATION 6 5 CALIBRATION Analog Outputs 6 5 1 Purpose Although the analyzer analog outputs are calibrated at the factory they can be trimmed in the field to match the reading from a standard milliammeter Both the low 0 or 4 mA and high 20 mA outputs can be trimmed 6 5 2 Procedure 1 Connect a calibrated milliammeter across the output you wish to calibrate If a load is already connected to the output disconnect the load Do not put the milliameter in parallel with the load Calibrate Sensor 1 Sensor 2 Output 1 Output 2 4 mA Output 1 Cal Meter 20 mA Output 1 Cal Meter Output 1 Trim Complete 2 Press MENU The main menu screen appears The cursor will be on Calibrate Press ENTER Choose the output you wish to calibrate The analyzer will simulate the low output current Change the value in the display to match the reading from the milliammeter The analyzer will simulate the 20 mA output current Change the value in the display to match the reading from the milliammeter If the calibration was successful the screen at left wil
98. successful but process pH is slightly different from expected value Calibration was successful but process pH is grossly wrong and or noisy pH readings are moderately noisy and tend to wander 9 6 1 Calibration Error During Two Point Calibration Once the two point manual or automatic calibration is complete the analyzer automatically calculates the sensor slope at 25 If the slope is greater than 60 mV pH or less than 45 mV pH the analyzer displays the Calibration Error screen and does not update the calibration Check the following 1 Are the buffers accurate Inspect the buffers for obvious signs of deterioration such as turbidity or mold growth Neutral and slightly acidic buffers are highly susceptible to molds which can change the pH of the buffer Alkaline buffers pH 9 and greater if they have been exposed to air for long periods might also be inaccurate Alkaline buffers absorb carbon dioxide from the atmosphere which lowers the pH If a high pH buffer was used in the failed calibration repeat the calibration using a fresh buffer If fresh buffer is not available use a lower pH buffer For example use pH 4 and 7 buffer instead of pH 7 and 10 buffer Was adequate time allowed for temperature equilibration If the sensor was in a process substantially hotter or colder than the buffer place it in a container of water at ambient temperature for at least 20 minutes before starting the calibration Using auto calibration helps
99. t the displayed value increases linearly reaching the final value after 5 seconds If the filter is set to greater than 10 seconds the analyzer applies either an adaptive filter or a continuous filter An adaptive filter discriminates between noise and real process change It filters changes below a fixed threshold value but does not filter changes that exceed the threshold It is best used in situations where the noise is relatively low A continuous filter dampens all changes The fil ter time setting is approximately equal to the time constant the amount of time required for the reading to reach 63 of the final value following a step change 3 pH CORRECTION Free chlorine is the sum of hypochlorous acid HOCI and hypochlorite ion OCI The relative amount of each depends on pH As pH increases the concentration of HOCI decreases and concen tration of increases Because the sensor responds only to a pH correction is necessary to prop erly convert the sensor current into a free chlorine reading The FCL uses either continuous live or manual pH correction In continuous live correction the analyzer continuously monitors the pH of the sample and cor rects the free chlorine reading for changes in pH In manual pH correction the analyzer uses the pH entered by the user for the pH correction Generally if the pH changes more than about 0 2 units over short periods of time continuous live pH correction is recommended If the p
100. the correct level 4 Review Section 6 2 9 7 2 Current Output Too Low Load resistance is too high Maximum load is 550 0 9 7 3 Alarm Relays Do Not Work Verify the relays are properly wired 9 8 SIMULATING INPUTS CHLORINE To check the performance of the analyzer use a decade box and 1 5V battery to simulate the current from the sen sor The battery which opposes the polarizing voltage is necessary to ensure that the sensor current has the correct sign 1 Disconnect the anode and cathode leads from terminals 1 and 2 on TB3 and connect a decade box and 1 5V battery as shown in Figure 9 3 It is not necessary to disconnect the RTD leads 2 the decade box to 2 8 MQ 3 Note the sensor current It should be about 500 nA The actual value depends on the voltage of the battery To view the sensor cur 7 JANOD SHLD rent go to the main display and press DIAG Choose sensor 1 The input current is the second line in the display Change the decade 8 ANOD box resistance and verify that the correct current is shown Calculate current from the equation 200 voltages in mV 9 CATH SHLD 10 FIGURE 9 3 Simulating Chlorine current nA nA resistance MQ The voltage of a fresh 1 5 volt battery is about 1 6 volt 1600 mV 70 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING 9 9 SIMULATING INPUTS pH 9 9 1 General This section describes how to simulate a pH input into t
101. w cell for chlorine sensor with bubble shedding nozzle 1 1b 0 5 kg 24039 01 Flow cell for pH sensor 1 1b 0 5 kg 24040 00 O ring kit two 2 222 and one 2 024 silicone O rings 1 1b 0 5 kg with lubricant 33812 00 Dust cap for constant head flow controller 1 Ib 0 5 kg 9322032 Elbow 1 4 in FNPT x in OD tubing 1 Ib 0 5 kg 9350029 Check valve 1 4 in FNPT 1 16 0 5 kg 33823 00 Outside tube for constant head device 1 1b 0 5 kg FIGURE 8 3 Replacement Parts for the Flow Controller Assembly used in Model FCL 02 58 MODEL FCL 1056 SECTION 9 0 TROUBLESHOOTING SECTION 9 0 TROUBLESHOOTING 9 1 OVERVIEW The analyzer continuously monitors itself and the sensor s for problems When the analyzer identifies a problem the word warning or fault appears intermittently in the lower line of the main display When the fault or warning message appears press the DIAG diagnostic key for more information See Section 9 2 A warning means the instrument or sensor is usable but steps should be taken as soon as possible to correct the condition causing the warning A fault means the measurement is seriously in error and is not to be trusted A fault condition might also mean that the analyzer has failed Fault conditions must be corrected immediately When a fault occurs the analog output goes to 22 00 mA or to the value programmed in Section 5 3 2 The analyzer also displays warning messages if a calibration is seriously
102. ween conduit connections Use grounding type bushings and jumper wires Unused cable conduit entries must be securely sealed by non flammable closures to provide enclosure integrity in compliance with personal safety and environmental protection requirements Unused conduit openings must be sealed with NEMA 4X or IP65 conduit plugs to maintain the ingress protection rating NEMA 4X Electrical installation must be in accordance with the National Electrical Code ANSI NFPA 70 and or any other applicable national or local codes Operate only with front and rear panels fastened and in place over terminal area Safety and performance require that this instrument be connected and properly grounded through a three wire power source Proper relay use and configuration is the responsibility of the user CAUTION This product generates uses and can radiate radio frequency energy and thus can cause radio communication interference Improper installation or operation may increase such interfer ence As temporarily permitted by regulation this unit has not been tested for compliance within the limits of Class A comput ing devices pursuant to Subpart J of Part 15 of FCC Rules which are designed to provide reasonable protection against such interference Operation of this equipment in a residential area may cause interference in which case the user at his own expense will be required to take whatever measures may be required to cor

Emerson FCL with 1050 Analyzer 1056 Instruction Manual

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